DGUV Information 209-071 English

209-071 DGUV Inormation 209-071

Sae maintenance o hydraulic systems

March 2015

Imprint About us Publisher: German Social Accident Insurance e.V. (DGUV) Glinkastraße Glinkastraße 40 10117 Berlin Tel.: 030 288763800 Fax: 030 288763808 E-Mail: in[email protected] Website: www.dguv.de

Subcommittee „Physical, chemical and biological media and effects upon health“, Expert Committee „Woodworking „Woodworking and Metalworking“ the DGUV. DGUV. This English translation was provided by the courtesy o Bosch Rexroth AG – The Drive & Control Company, 97816 Lohr am Main, Germany. Design: German Social Accident Insurance e.V. e.V. (DGUV), Media Production March 2015 issue English translation o the German DGUV Inormation 209-070 (BGI/GUV-I 5100) o 01/2014 DGUV Inormation 209-071 E available rom the competent German social accident insurance institution or on www.dguv.de/publikationen

Imprint About us Publisher: German Social Accident Insurance e.V. (DGUV) Glinkastraße Glinkastraße 40 10117 Berlin Tel.: 030 288763800 Fax: 030 288763808 E-Mail: in[email protected] Website: www.dguv.de

Subcommittee „Physical, chemical and biological media and effects upon health“, Expert Committee „Woodworking „Woodworking and Metalworking“ the DGUV. DGUV. This English translation was provided by the courtesy o Bosch Rexroth AG – The Drive & Control Company, 97816 Lohr am Main, Germany. Design: German Social Accident Insurance e.V. e.V. (DGUV), Media Production March 2015 issue English translation o the German DGUV Inormation 209-070 (BGI/GUV-I 5100) o 01/2014 DGUV Inormation 209-071 E available rom the competent German social accident insurance institution or on www.dguv.de/publikationen

Sae maintenance o hydraulic systems

DGUV Inormation 209-071 E

March 2015

Content

Disclaimer and Legal notice .................

5

Preliminary remark ..............................

6

1

1.1 1.2 1.3 1.4 1.5

2 2.1 2.2 2.3 2.4 3 4 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8

5 5.1 4

Maintenance o machines, systems, and vehicle attachments with hydraulic equipment ...... 7 General .................................. 7 Qualification o maintenance technicians................................... 8 Hazards when working on hydraulic systems ................................. 9 Electrical hazards................... 13 Planning the works................. 13 Handling hydraulic luid ......... Skin protection ...................... Leaking hydraulic luid ........... Searching or leakages ........... Replacing the hydraulic luid .. Troubleshooting.....................

16 16 21 22 23 24

Working on hydraulic components........................... General .................................. Pipelines................................ Hose assemblies.................... Hydraulic cylinders................. Pumps and hydraulic motors .. Valve blocks........................... Accumulator systems ............. Filters.....................................

28 28 29 31 43 44 45 47 48

Working on machines and systems .......................... General ..................................

51 51

5.2 5.3 5.4

6 6.1 6.2 6.3

6.4

6.5

7 7.1 7.2

Working on machine tools ...... Working on hydraulic presses . Working on hydraulic scissors lifs ........................................

Working on the mobile hydraulic system ................... General .................................. Working on industrial trucks ... Working on hydraulically driven vehicle attachments and superstructures and vehicle cranes65 Working on earth-moving equipment and other automotive machines.................................... Working on water vehicles ......

54 55 56

57 57 63

67 71

7.4

Required tests........................ General .................................. Checking or proper installation and sae unction ................... Checking or sae provision and use.................................. Legal bases or the tests.........

74 75

8

First Aid .................................

76

7.3

74 74 74

Annex 1 A Troubleshooting .................. 78 B Notices on maintenance ...... 86 C Scope o visual inspection ... 88 D Scope o testing o unctional test ........................................ 89 E Scope o testing o sae provision and use.................................. 90 F Involvement o staff members 92 Annex 2 Provisions, Rules and Reerences 94

Disclaimer and Legal notice

The German Statutory Accident Insurance “Deutsche Gesetzliche Unallversicherung” (DGUV) and the Expert Committee Woodworking and Metalworking “Fachbereich Holz und Metall” (FBHM) and the translator make no express or implied warranty with regard to the sae maintenance procedures and rules or efficiency or any particular purpose. The sae maintenance procedures and rules are made available solely on an “as is good practice” basis, and the entire risk as to their saety, efficiency and to the environmental protection is with the user. Should the sae maintenance procedures or rules prove deective, the user (and not the DGUV or the FBHM or the translator any other party) shall bear the entire cost o all necessary corrections, repair or all incidental or consequential damages. The DGUV or the FBHM or the translator shall not be liable or any incidental or consequential damages in connection with or arising out o the use o this saety inormation on hydraulic maintenance and its rules. The committee o experts FBHM is composed o representatives o the German institutions or statutory accident insurance and prevention (Berusgenossenschafen), ederal authorities, social partners, manuacturers and users and subdivided into subcommittees. The inormation “DGUV Inormation 209-071” is based on experience gathered by the FBHM and its subcommittee in the field o hydraulic equipment o machinery and plants. It should help to speciy the sae maintenance procedures o hydraulic equipment that are used in machinery and plants, and that are included in the scope o the European Machinery Directive. The particular provisions or different applications (e.g. in the mining industry or similar) have to be considered. The present document DGUV Inormation 209-071“ Sae maintenance o hydraulic systems” is the English translation o the German inormation BGI/GUV-I 5100 “Sicherheit bei der Hydraulik-Instandhaltung”, edition January 2014, now listed as DGUV Inormation 209-070, and it replaces the ormer English edition BGI 5100e o April 2008. The provisions according to individual national laws and decrees in other countries remain unaffected by this translation o the German inormation DGUV Inormation 209-070. The requirements o the individual national legal rules and o manuacturers instructions (including manuals) apply without reservation. In order to get detailed inormation it is necessary to read the relevant wording o the national rules and instructions.

5

Preliminary remark

Since 1950, more and more hydraulic components have been produced as modular elements and used in systems or machines to meet widely varying requirements. The particular advantage o hydraulic systems is their high energy density, i. e. small components can be used to generate high outputs. At the beginning, hydraulic control elements were exclusively operated manually. In the course o the technical development, the combination with electric or electronic parts has been promoted increasingly. Today, or example, automated production systems consist o numerous linked, complex assemblies. The possible applications o hydraulic systems are very diverse. They range rom the micro area via machine and systems engineering up to the aerospace industry. In the field o hydraulics energy is transerred via a hydraulic luid that is used to generate movements or orces. In general mechanical engineering, pressures up to 350 bar and in special cases, e. g. or static orming technology, pressures up to 5,000 bar are used. This inormation addresses to persons who plan and carry out maintenance work on machines and systems with hydraulic equipment. As maintenance procedures on machines ofen require the intervention in areas that are not accessible during normal system operation, this work requires the implementation o special protective measures (see also inormation “Instandhalter” (BGI 577)). This inormation mentions descriptions o hazards and measures or preventing them and gives advice or implementing maintenance work on hydraulic equipment in a sae manner. This inormation provides support or identiying and assessing risks and deriving suitable measures in accordance with German general technical rules or operating saety TRBS 1112 „Instandhaltung“ (Maintenance) with regard to the specific hazards in maintaining hydraulics. This inormation describes measures that must be taken into account when carrying out maintenance work on machines and plants with hydraulic equipment. Apart rom the description o planning and carrying out maintenance work, this inormation also deals with troubleshooting and re-commissioning afer repairs were carried out. 6

1

Maintenance o machines, systems, and vehicle attachments with hydraulic equipment

1.1

General For all works on hydraulic systems and equipment, the inormation given by the machine or system manuacturer regarding knowledge and qualification, as well as commissioning and maintenance procedures have to be observed. Spare parts have to meet the specifications o the machine manuacturer. This means that all parts to be installed have to be selected especially in accordance with the maximum operating pressures and suited or the hydraulic luid used in the system. Hazard warnings and saety measures, amongst others rom the saety data sheet o the hydraulic luid used, have to be incorporated and implemented in the operating instructions (see section 2.1). Remodeling machines and systems can constitute a substantial modification in the meaning o the German Product Saety Act, at which additional saety requirements and urther measures may have to be taken into account. Thus, the manuacturer should be contacted beore any remodeling works.

Note Remodeling a machine may require a new assessment o conormity.

7

Fig. 1 Maintenance technician during maintenance work

1.2

Qualification o maintenance technicians The maintenance technician has to be amiliar with the design o hydraulic components and systems through his proessional training, occupational experience, and activity. He should have finished his vocational training, e. g. as • industrial mechanic, • mechatronics technician, • systems mechanic, • automobile mechanic, • agricultural machine mechanic or • have passed advanced training as hydraulics technician. Furthermore, the maintenance technician has to be instructed regarding the possible hazards and the resulting protective measures. Fundamental obligations o the employees result rom the accident prevention regulation „Basic principles o prevention“ (BGV/GUV-V A1), see Annex 1 letter F. For planning and implementing maintenance works, it is required to understand at least • the operating instructions (including notes on maintenance), • the unctional and wiring diagrams, • the operating modes, • the machine sequences, and • the connections to other technologies (mechanic, electric, electronic).

8


The application o the methods o systematic troubleshooting has to be known. I the knowledge mentioned above is insufficient, system-specific inormation have to be requested rom the machine manuacturer. The work on electric parts o machines and systems is associated with special hazards. Thus, this work must only be conducted by persons who are technically trained and instructed in electrotechnology, e. g. electricians.

1.3

Hazards when working on hydraulic systems A hazard analysis has to be conducted or maintenance work and documented together with the resulting protective measures (see also TRBS 1112, section 4, paragraph (2)). The risk assessment or the maintenance technician must be conducted by the head o the maintenance department. For recurring, identical maintenance work (e. g. replacement o hose assemblies, valves or cylinders), it may be sufficient to carry out risk assessments once and use this as a basis or operating instructions and regular instruction.

Note: In case of particular hazards (e. g. due to reciprocal effects with other work or at new, unknown places of operation or in the premises of customers), a risk assessment must also be conducted before maintenance work is started and, if necessary, it may have to be coordinated with the responsible safety and health coordinator of the customer. Working on hydraulic systems can lead to the ollowing hazards: • uncontrolled leakage o the hydraulic luid, • accidental machine movements, • risk o burning at hot suraces or hot hydraulic luid, • parts coming off or bursting, • skin diseases, • noise.

9


Uncontrolled leakage o the hydraulic luid The leakage o hydraulic luid has to be expected i lines rupture, i connection elements that are still pressurized become loosened, i hydraulic hose assemblies (see figure 2) are damaged, or i inadmissibly high orces are applied. The consequences can be: • damage to the eyes, • intrusion into the skin (intoxication), • scalding by hot hydraulic luid, • risk o fire, i there are ignition sources (e. g. oils on hot suraces), • slipping danger on work stations and traffic paths, • hazards due to accidental machine movements, • environmental hazards, (e. g. intrusion into or release to the ground/ groundwater). Inadmissibly high orces can occur due to • improperly set pressure valves, • modifications, e. g. on pressure relie valves, • improperly rated valves (switching too ast), • loads applied externally, • accidental pressure intensifications on cylinders.

Accidental machine movements can be triggered by • accidental operation o command or control devices, such as buttons, levers, controlling light barriers, proximity switches, manual overrides, as well as intererences by magnetic fields, • errors in the control system, • energy separation, energy supply, residual energy, • parts ailure, • contamination o the hydraulic luid.

10


Residual energy in a system can be present i • accumulators (hydraulic/pneumatic) exist in the system, • loads are maintained in elevated positions, • clamping orces exist, • there are tensions between parts. Parts ailure can result rom e. g. • excessive system pressure, • wear and tear and material atigue (e. g. valve springs), • stuck valves, • overload due to excessive dynamic pressure peaks, • improper or contaminated hydraulic luids.

Risk o burning on hot suraces and hot hydraulic luid: • machine parts that are hot during operation, such as line assemblies, pumps, motors and • escaping hydraulic luid, e. g. when lines are opened or components are removed Parts coming off or bursting can be the result o • overloaded components, e. g. due to excessive operating pressures or pressure peaks, • material atigue, • parts selected improperly This also comprises whipping hydraulic hose assemblies ruptured on one end.

11

Fig. 2

Bursted hydraulic hose assembly

Contact with hydraulic luids can lead to effects hazardous to skin (see section 2). Vapors o hydraulic hydraulic luids can cause airway air way irritations when inhaled.

Noise emissions are not only caused by the pump unit, even the noise o machines generated during operation can cause a substantial level o noise, e. g. during troubleshooting, test operation and others. Thus, the maintenance technician o the hydraulic system has to wear ear protection in case o noise emissions hazardous to health. Depending on the maintenance work one or more hazards can occur simultaneously. Thus, several protective measures measures have to be used. The most important impor tant protective measures are explained in the individual sections o this inormation. I required, reerences are made to other BG inormation.

Note: Should the risk assessment of maintenance work identify explosion hazards, the technical rule for operating safety (TRBS) 1112 part 1 “Explosionsgefährdungen bei und durch Instandhaltungsarbeiten – Beurteilung und Schutzmaß-nahmen” (explo sion risk arising during and due to maintenance work – assessment and protective protective measures) must be applied.

12


1.4

Electrical hazards Working on electric parts o machines and systems can result in special hazards, such as • direct and indirect contact with live or conducting parts, • shock currents, • electric arcs/discharges, • voltage diversion, (e. g. with improper grounding), and especially hazards due to working in confined spaces, which also comprise the interior o machines and metallic vehicle superstructures, see (inormation “Working in confined spaces” (BGI 534)). Thus, this work must only be conducted by persons technically trained and instructed in electrotechnology, e. g. electricians.

1.5

Planning the works Accidents most ofen occur because o no or o r insufficient organizational preparation o the maintenance works. Implementing the works when being pressed or time is another reason. Furthermore, ofen only repair work is perormed instead o determining and remedying the reasons or the ailure. Moreover, years o routine can lead to overestimation o one’s own capabilities or to misinterpretations, i the practiced way o working is no longer challenged. A precondition or sae maintenance works is planning the works thoroughly, thoroughly, including the execution o a risk assessment assessment and considering or preparing prepari ng maintenance instructions. Planning comprises: • the scope and the course o the maintenance procedure, • required protective measures according to the risk assessment, • the selection o maintenance technicians according to their qualification, • the required number o maintenance technicians according to the extent o the work to be perormed, 13


and • the work equipment to be used, such as tools and devices. When determining the work steps, possible possible hazards have to be minimized by protective measures. I new hazards occur during the works, these have to be minimized as well by risk assessment and additional protective measures. The maintenance instructions should include at least the ollowing: • notices on systematic troubleshooting (see section 3), • provision o components that may need to be replaced, special tools, a nd aids, • securing the circuit breaker o the energy supply, or example electrical, hydraulic, pneumatic, • reduction o residual energies (in connected parts as well), • supporting elevated loads, • method(s) or depressurizing the system, • checking the depressurized condition, • i required, urther protective measures to be taken (see Annex 1 letter B). Sae access to the points o contact and to sae standing suraces has to be provided or perorming peror ming the maintenance works, e. g. work platorms, platorms, other platorms. The most important saety measures or maintaining hydraulic systems can be summarized in the five-finger rule o luid power technology :

Note

Five-finger rule o luid power technology 1. Interrupt energy supply 2. Prevent unintentional re-closing (figure 3), 3. Depressurize the system, including all existing accumulators, lower or support elevated loads, reduce residual energies 4. Check depressurization 5. Prevent hazards caused by adjacent systems.

14

Fig. 3

Securing against unintentional re-closing by lockable ball valves.

I several persons work together during the maintenance work on a hydraulic system, one o them has to be appointed who determines, monitors and coordinates the work and the protective measures. Along with the direct hazards caused by the hydraulic system, secondary hazards have to be taken into consideration as well, e. g. risks o alling rom heights. In order to improve occupational saety or maintenance works on a systematic basis • the causes o aults and ailures should be documented and evaluated, • the implementation and effectiveness o measures taken should be checked, • work implemented should be documented, • risk assessments and maintenance instructions should be checked and updated, i required, and • any technical modifications implemented should be recorded in the documentation o the machine or system.

15

2

Handling hydraulic luid

2.1

Skin protection Maintenance technicians or hydraulic systems are used to having „dirty hands“ at work. The intensive daily skin cleansing procedure is tolerated apparently without any problems, so that normally, only little thought is given to the question whether the skin – the largest human organ – tolerates this without being damaged in the long run. The alloy components and additives contained in the oils and ats can have allergizing or sensitizing effects. A lack o consciousness or the aorementioned is one reason w hy skin diseases range amongst the most requent work-related diseases in metal-working companies. The organ skin is the link between the human immune system on the one hand and the „external world“ on the other hand. Especially the ats on the external skin layer orm an efficient but vulnerable protection against harmul inluences. Frequent washing, especially with substances solving the ats, damages this protective layer. I the body is no longer able to repair these damages within the work breaks, the result is dry skin with ormation o ruptures and redness, shortly the „wear eczema“. Secondly, ofen an “allergic eczema” additionally „engrafs“ during the urther course, as substances potentially causing allergies can intrude into deeper regions o the skin organ more easily i the skin is already damaged. Depending on the personal disposition, such reactions can occur a relative short time upon the first skin exposures or upon many years or decades o executing skin exposing activities. I a work-related allergic skin disease has established, the consequences – proessional and private – are ofen serious. As contact with substances causing allergies normally cannot be prevented completely, losing the job is possible.

What can be done? There are many options or maintaining a mostly healthy skin even during strongly contaminating activities. Firstly, the most important precondition is that everybody develops the proper understanding or the vulnerability o his own skin.

16

No.: 000 Sample

Operating instructions according to §14 GeStoffV

Date: 27.01.2012

(German Ordinance on Hazardous Substances) Operation: Field o application: Workshop, warehouse

Hydraulic oils Hydraulic oils with high viscosity: Highly refined mineral oils with additives

Hazards or human beings and the environment Hydraulic oils are lammable. In connection with air, vapors emitted during strong heating and atomized sprays can orm explosive mixtures. Clothes soaked with oil are subject to an ignition hazard. Frequent or long-term contact with the products, clothes soaked with oil as well, can cause skin diseases such as inlammation, skin rash, petroleum acne or example. Products subject to high temperatures while being used can accumulate with harmul Substances. Leaking hydraulic oil is hazardous to waters.

Protective measures and rules o conduct Store and fill hydraulic oils above drip pans only, avoid splashing. Do not overfill drip pans with containers and do not use drip pans to store other materials. Keep away rom ignition sources, do not smoke. Do not atomize lubricants. Keep containers closed and protect against heating. Store soaked cleaning cloths in non-inlammable, closed containers. Replace cleaning cloths on a regular basis. Label filled containers, replace aulty labels. Never use ood containers or containers that could possibly be conused with the same. Hand protection:

or long-term, use resistant gloves protecting against chemicals

Skin protection:

see skin protection scheme

Avoid contact with skin and clothes. Take off soaked clothes immediately and re-wear them upon cleansing. Do not put used cleaning cloths into the pockets o the working clothes. Upon handling the materials wash your hands and apply care creme. Do not use any solvents, thinners, benzine or others or skin cleaning purposes.

Behaviour in case o danger (emergency telephone: see placard) Upon leakage immediately soak up using oil binder (............................) and place into waste container; ventilate room thoroughly. Caution: Slip hazard due to slippery loor. Fire extinguisher or fire class B, no water. .................. In case o fire there is the danger o bursting closed heated containers. Leave oil warehouse in case o danger. Escape route: see identification o the escape routes and emergency exits

First aid (first aider: see placard) Upon skin contact: Upon eye contact: Upon swallowing: Upon oil injection:

wash thoroughly using soap and water, take off soaked clothes beorehand. with open palpebral fissure and in direction o the external palpebral fissure lush or 10 minutes with running water, contact eye specialist. Do not stimulate vomiting, contact a doctor. e. g. upon subcutaneous intrusion o oil contact doctor immediately!

Appropriate disposal Collect wastes in labeled, non-inlammable containers (............................); keep waste containers and empty containers closed, empty containers at the end o the shif at the latest or remove rom the work area. Date, Signature:.................................

Fig. 4

Sample o operating instructions or hydraulic oil

17


The entrepreneur is responsible or regulating skin protection within the company, e. g. using a skin protection scheme (see figure 4). In doing so, specialists (company physician, supervisor) should be integrated and corporate experience should be taken into consideration.

2.1.1

Work clothes No special protective clothes are specified or the maintenance technician or hydraulic systems. Work clothing worn and contaminated in addition to or to protect the private clothes have to be cleansed on a regular basis. There should be at least two, better three overalls or every maintenance technician, in order to provide or immediate replacement even in case o unoreseeable contaminations with hydraulic luids.

Note Contaminated clothes have to be taken off immediately. Contaminated cleaning rags must not be put into the trousers.

Naturally, the hands have the most intensive contact with the possibly harmul substances. Appropriate protective gloves provide best protection (see figure 5). Appropriate means that they are especially resistant regarding the substances they are supposed to protect against. For handling hydraulic, machine, motor, and transmission oils, gloves consisting o the ollowing materials are considered appropriate: • acrylonitrile butadiene, rubber, nitrile rubber, nitrile latex (NBR), • chloroprene rubber (neoprene) (CR), • isobutylene isopropene rubber (rubber) = butyl rubber, butyl (IIR). Different tasks or maintenance works require the normal protective clothes to be supplemented, e. g. • overhead works: gloves with cuffs, • troubleshooting and leakage tests: helmet with visor, • component replacement: one-way trousers type 4.

18


Fig. 5

Personal protective equipment or oil change

Note No gloves must be worn in the vicinity o rotating parts.

2.1.2

Skin agents This generic term comprises: • skin protection agents, • skin cleansing agents, and • skin care agents. The harmul substances to be expected are substances insoluble in water. Some statutory accident insurers and skin care agent manuacturers developed skin protection schemes differing in content and color in dependency on the effects o individual harmul substances. The yellow skin protection scheme, shown in figure 6, lists a selection o appropriate skin protection agents, skin cleansing agents, and skin care agents to be used in case o contact with substances insoluble in water.

19


Basically, the objective should be to clean the skin as gentle as possible, as well as to provide the skin especially with at and moisture afer work, along with the appropriate skin protection agent. Using appropriate skin protection agents or protective gloves as consequently as possible reduces or prevents contamination o the skin and thus allows or using more gentle skin cleansing agents.

Skin protection and hygiene scheme „maintenance“ Gloves

Skin contact to hydraulic luids that cannot be mixed with water

Sahara 100 Dextram 376 Contact NB20C SolVex 37-675

Skin agent or Skin protection

Skin cleansing

Skin care

Lindesa O Liga pro Herwesan Olio Sansibon pr 88 Travabon

Lindapur plus Ivraxo sof B Herculan Topscrub pr clean plus Praecutan plus

Lindesa Ligana HPC Herwe Cura Cura Sof pr 2000 Stokolan

Products taken rom: BGI 658 “Hautschutz in Metallbetrieben, Stand 11/2008)” BGI-Inormation “Skin protection in metal processing companies” (BGI 658) (The list makes no claim to be complete)

Fig. 6

2.1.3

20

Skin protection and hygiene scheme

Use o skin agents Skin agents can only achieve the desired success i all three skin agents (skin protection, skin cleansing, and skin care agents) are used • on a regular basis (daily, beore starting to work, beore and afer breaks, and afer work), and • properly (see manuacturer’s instructions).


2.2

Leaking hydraulic luid Leakages o hydraulic luid have to be prevented, as oiled work suraces and treads on machine platorms, as well as oiled workshop loors bear slip dangers, tools could slip more easily on wrench suraces or parts, and fire hazards could be the result. As personal protection equipment worn gloves have to be kept ree o hydraulic luid or replaced. In order to avoid wetted machine platorms or vehicle treads, appropriate drip pans are useul. This also includes adapted pans or maintenance work on the mobile hydraulic system outdoors or on construction sites. Removed hydraulic components such as pumps or valves still contain residual amounts o hydraulic luid and have to be stored intermediately in sufficiently dimensioned pans. Inserting drip pans into the workshop loor below the machines prior to their installation, provides or efficient protection against slip dangers on workshop loors. I required, oil binders, sweeping equipment, and disposal containers have to be taken to the danger spot immediately, in order to hold leaked hydraulic oil and thus eliminate slip hazards. Oil absorbing cloths help to remove residual oil in machine parts.

Fig. 7

Trolley or transporting oil binders

21


Note Leaked hydraulic luids have to be removed immediately and completely.

In order to reduce leakages o hydraulic luids, some machine manuacturers permit using vacuum pumps (see figure 8) generating a slight vacuum in the hydraulic tank upon closing all tank air vents using a connection via special tank covers.

Fig. 8

2.3

Vacuum pumps or mobile hydraulic tank in 24 VDC and 230 VAC design

Searching or leakages Searching leakages on machines has to be conducted systematically at reduced system pressure, i possible, and with personal protection equipment, e. g. gloves, protective rubber clothes, goggles, or helmet with visor, and by using aids such as blotting papers. It has to be taken into account that the hydraulic luid leaking rom the leakage points (cracks, fissure) under high pressure causes very serious injuries or

22


intoxications when coming into contact with the human body! Even the use o protective clothes, including protective gloves, does not provide or complete protection.

Note In any case, keep away rom possible leakage points.

2.4

Replacing the hydraulic luid The hydraulic luid used has to comply with the provisions o the machine manuacturer or the system or component manuacturer. In this, the materials o the sealing elements used have to be taken into consideration. When replacing the hydraulic luid it has to be paid attention to the act that no contamination enters the tank or other parts o the hydraulic circuit. In order to achieve the desired cleanliness class, reshly delivered hydraulic luid has to be filtered as well.

23

3

Troubleshooting

Naturally, preventive maintenance and repair measures, especially checking the oil cleanliness on a regular basis, are the best method to minimize errors and ailures in the run-up already. Nevertheless, errors and ailures can occur when operating a hydraulic system or machine, which impair the general operational sequence but also the saety o the hydraulic system or machines. Apart rom the impairment o the product quality, this can lead to hazards (see section 1.3) which no longer ensure sae working with the machine. Thus, it is important that the machine operator reports all ailures and errors to the supervisor or the maintenance department immediately. These persons decide whether it is possible to continue work with the machine or whether the machine has to be repaired immediately.

Note Errors in hydraulic systems or machines have to be reported to the supervisor immediately.

Beore starting troubleshooting, the procedure has to be determined. Along with planning the proper troubleshooting, this also comprises the measures or securing the work area (i. e. the danger and effective range), as well as the required protective measures.

Note Troubleshooting and repair works must only be conducted by trained personnel.

At the beginning o troubleshooting, the required technical documents and inormation should be available, e. g. operating instructions, circuit and electrical diagrams, including measuring points and a list o items. I no hydraulic circuit diagram can be ound or older systems, a circuit sketch should be established on the basis o design, signposting, and labeling o the parts. 24

Troubleshooting

The machine operators should be questioned regarding error behavior, ailures, and reactions o the machine and system. I a maintenance book or log exists, it should be used to investigate i this or similar ailures have already occurred. Furthermore, the er ror lists in the operating instructions o the manuacturer have to be taken into consideration.

Note For troubleshooting, the technical documents o the system/machine have to be available.

I troubleshooting requires working methods which deviate rom those applied or normal operation, e. g. test runs, setting, start-up, or is it necessary to run one cycle or several cycles with the deective machine in order to localize the errors, it has to be ensured that saeguarding equipment (movable saeguarding equipment, two-hand control devices, light barriers) on the machine is active in this phase as well. On the basis o the error that occurred, urther machine-specific measures (and organizational measures) may have to be taken in order to avoid employees being endangered during troubleshooting (wide area saety ence using chains, instruction plates, reduced speed, and reduced pressure). During troubleshooting, operating modes should be applied in which individual unctions are operated outside the automatic operation at reduced speed, in tip operation (hold-to run control device), with enabling switch, or in the operating mode „Set-up/Hand“. Attention must be paid to the act that dangerous ollow-up movements are triggered when passing position switches, e. g. also or automatic program-controlled tool or work piece change, start-up o accessory devices.

Note Troubleshooting must only be conducted with activated saeguarding equipment. I required, urther organizational measures are necessary.

25

Troubleshooting

I troubleshooting also can be done with the machine turned off or i the machine is turned off or error correction upon localizing the error, the five-finger rule mentioned in section 1.5 has to be observed.

Note Observe the five-finger rule o luid power technology.

I the control system is not a purely hydraulic system, but the hydraulic system is operated as part o an electro-hydraulic control system, it may be necessary to have the troubleshooting procedure conducted by a specialist electrician. In case o complex systems operated with electronic control systems, it may also be necessary to call a specialist or electronic hardware or sofware. In this case, i several persons work on the machine or troubleshooting purposes, it is imperative to provide or sufficient coordination o the activities on the machine. This especially holds true i the machine operator has to be incorporated into the activities. Furthermore, hazards caused by adjacent systems or hazards to persons working on adjacent systems have to be prevented.

Note For electro-hydraulic systems, a specialist or electrical engineering or electronics has to be called. Activities o several persons have to be coordinated.

Even when pressed or time, ollowing a systematic and targeted procedure is imperative, as a random and rash disassembly or adjustment activities could result in the act that the initial error cannot be identified anymore.

26

Troubleshooting

It is recommended to document the implemented work steps, adjustment values, as well as their modifications. All modifications to the system have to be documented in a traceable manner, e. g. in the machine documentation and, i required, in a maintenance book or log. A list o eliminated ailures and error causes supports troubleshooting procedures in the uture. Many hydraulic system manuacturers have developed comprehensive service inormation in which they describe systematically possible malunctions and their causes or possible sources and measures or eliminating them as the technical reasons or errors and the measures or their elimination can vary considerably. Annex 1 letter A shows a general troubleshooting tree or hydraulic components. Typical errors include or example: • clogged hydraulic filters, • stuck valves due to contaminations, • unexpected start-up o the machine due to tipping/triggering position/stop switches • ailure o valves due to spring rupture. The reason or part ailure should be determined. Notes: If the hydraulic energy has to be maintained for troubleshooting or due to other reasons, the provisions of the manufacturer have to be observed. Regarding the re-commissioning procedure, further safeguarding measures have to be ob served, see sections 5.1.2 and 6.1.9.

27

4

Working on hydraulic components

4.1

General When working on different hydraulic components, numerous saety-relevant asaspects have to be considered by the maintenance technician. Sections 5 and 6 deal with the particularities or certain machines and systems, and those or the mobile hydraulic system. Basically, Basically, only spare parts par ts approved by the manuacturer should be replaced or installed. It is imperative to observe provisions and notices o the manuacturer regarding special knowledge or training o the maintenance technician. The hydraulic system has to be protected against contaminations introduced rom the outside as ar as possible. Flushing provisions on part o the manuacturer have to be observed. Spare parts to be installed have to be ree o contaminations. All parts installed by the maintenance technician have to be selected in accordance with the operating pressures and hydraulic luids. Due to the partially relatively large masses or the installation position and the position o the center o gravity o hydraulic components, suitable lifing gear and lifing accessories must be provided or disassembly disassembly and assembly and or transportation. I it is possible to conuse line connections, these have to be marked clearly by the maintenance technician beore being disconnected. It is imperative to observe the provisions o the manuacturer regarding commissioning afer completed maintenance works.

Fig. 9 Central hydraulic system at commissioning 28


4.2

Pipelines Pressurized fittings o pipelines must not be opened. I pipelines are replaced, standardized seamless cold-drawn cold-drawn precision steel pipes have to be used. When selecting these pipes, the requirements o the machine manuacturer with regard to material characteristics, wall thickness, cross sections and the admissible operating pressures have to be observed (see parts list). Some connection element manuacturers rate the nominal pressures in deviation rom the standards. Thus, parts having the same dimensions can be characterized by substantial differences regarding the nominal pressures. Similar thread sizes o different systems (metric/imperial) must not be conused!

Note When procuring spare parts attention must be paid to the act that parts having the same dimensions can be characterized by different nominal pressures and thread types!

I pipelines have to be re-routed within the ramework o maintenance work, these have to be attached by pipe clamps in an adequate manner.

29


The ollowing distances are recommended: External pipe diameter

Recommended spacing* between two pipe clamps (according to DIN EN ISO 4413) From a pipe connection

Between two supports in the case o a straight pipe

From a pipe bend

up to 10 mm

0.05 m

0.6 m

0.1 m

over 10 mm to 25 mm

0.10 m

0.9 m

0.2 m

over 25 mm to 50 mm

0.15 m

1.2 m

0.3 m

over 50 mm

0.20 m

1.5 m

0.4 m

[*Reproduced by permission o DIN Deutsches Institut ür Normung e. V. For applying the DIN-standard, DIN-stand ard, the recent issue which can be obtained rom Beuth Verl Verlag ag GmbH, Burggraenstraße 6, 10787 Berlin, Germany is decisive.]

In doing so, it has to be observed that the pipeline is not damaged, e. g. attaching it by welding is inadmissible. No other parts must be attached to pipelines. The pipe elbows have to be bent taking into account the details regarding the bending radii and the use o appropriate devices de vices ( e. g. pipe bending machine). The pipes must not be buckled when they are bent. Pipes subjected to heat treatment have to be cleansed and descaled. Beore being installed, pipeline components always must be deburred, cleansed, and installed in accordance with the provisions o the fitting suppliers.

Fig. 10 Proper attachment o pipelines with pipe supports 30


I line connections can be conused, these have to be marked clearly and permanently by the maintenance technician beore being disconnected. During assembly, the newly installed connections have to be tightened in accordance with the manuacturer’s instructions, e. g. using the torque wrench or according to specified angle o twist, in order to avoid shear orces and tensions. Pipelines and fittings have to be checked or leaks up to maximum operating pressure beore they can be approved. I pipeline fittings show leakages, these have to be remedied. For this, depressurized condition has to be established first. Aferwards, the ollowing measures can be implemented: • checking the tightening torques o fittings, • checking the tightening torques o lange connections, • replacing the seals.

4.3

Hose assemblies

4.3.1

General Hose assemblies are only used on machines and vehicles i hydraulic connections are required between moving parts o a hydraulic system or i an easier replacement o power units (e. g. auxiliary power units on earth-moving and arm machines) is wanted (see figure 12). Using hose assemblies can also reduce pressure peaks in the hydraulic system or compensate vibrations between individual parts.

Fig. 11 Pipeline routing in a large machine 31

Fig. 12 Hydraulic hose assemblies on an excavator

In general, hoses consist o an elastomer compound o internal and external rubber layer and pressure carriers consisting o one or several layers. Plastic hoses are used as well having technological advantages and disadvantages (see also section 4.3.9). The term hose assembly describes the assembly and the unit o hose and fitting mounted aferwards.

Hose line

=

Hose +

Fitting

Hose assembly: marking

manuacturer`s name or identification

manuacturer`s name or identification

number o European Standard

max. working pressure o the assembly in bar

type

the last two digits o the year o manuacture

nominal bore

month o manuacture

quarter and the last two digits o the year o manuacture Hoses shall be marked durably with at least the above named inormation, and the marking shall be repeated at least once every 500 mm.

Fig. 13 Structure and labeling o a hose assembly 32

Hoses assemblies shall be marked durably with at least the above named inormation.


Faulty integration, ageing, and mechanical damage can result in the hose assemblies bursting. Thus, corresponding care should be exerted when selecting, assembling, mounting, and operating hose assemblies. A hose has to be labeled consecutively and durably as ollows, see rule “Hydraulic hose assemblies” (BGR 237): • manuacturer sign, • hose type, • nominal width, • date o manuacture (quarter and year), as well as the • number o the relevant hose standard. A hose assembly has to be labeled durably as ollows: • manuacturer’s name or short sign, • maximum operating pressure with indication o the unit, • date o manuacture (year/month), see also BGR 237 or DIN 20066.

Note Hoses and hose assemblies o unknown origin and / or with incomplete marking must not be used!

4.3.2

Selection o hose, fitting, and hose assembly or replacement In principle, hoses have to be replaced in accordance with the manuacturer’s instructions. I no manuacturer details are available, the ollowing procedure has to be ollowed: Hose, fitting, and hose assembly have to be selected in such a way that • the admissible maximum operating pressure o the individual components is not exceeded or the operating conditions to be expected taking account o pressure peaks, • those operating pressures are taken into account, the control system has been designed or, • the thermal resistance is ensured, 33


• changes in lengths and outside diameters o the hoses were taken into account, • the minimum bending radius is adhered to (depending on hose type and nominal • •

• • •

width), abrasion characteristics are considered, the cross-sections are sufficiently dimensioned, so that no inadmissible dynamic pressures are generated that or example could impair the ree return low to the tank, the compatibility o hose and sealing materials with the hydraulic luid used is given only parts are used that comply with the requirements o European or international product standards, such as EN, ISO, SAE standards, designs o hose assembly fittings consisting o a (drilled) pipe socket with olive are not used, as these do no longer correspond to the state-o-the-art and have led to accidents due to slipping tools in the past.

Note It has to be checked i the hose assembly is suitable or the intended use regarding pressure and low.

4.3.3

Creating a hose assembly It is recommended to purchase hose assembly as ully assembled parts. I a hose assembly is made by onesel, it has to be observed that the selected parts (hose and fitting) are compatible regarding their dimensions, shape, and pressure stage. For this, it is imperative to observe the provisions o the manuacturers o hose and fitting. Proo o sae unction must be urnished by an appropriate test procedure (see section 4.1.2 o BGR 237). I the integration is conducted by onesel, only equipment and devices approved by the fittings manuacturer must be used or this (see figure 14). A sae hose integration urthermore implies detailed knowledge o the integration procedure, the devices, and parts. Conducting the integration without this knowledge and without these devices is negligent and inadmissible rom a saety point o view.

34


The so-called “improvised cobbling together” o hose assemblies on the bench vice is negligent!

Fig. 14 Device or pressing hose fittings

Note Hose assemblies should only be purchased rom the hose assembly manuacturer in pre-assembled state.

35


4.3.4

Installing the hose assembly In order to ensure the unctionality o hose assemblies and to not shorten their lietime due to additional loads, the ollowing has to be observed. 1. Hose assemblies have to be installed in a way that their natural position and movement is not impaired (scour marks have to be avoided), see also figure 15. 2. Hose assemblies must not be subject to tensile, torsional, and compression loads caused by external inluences during operation. 3. The smallest bending radius o the hose specified by the manuacturer must not be allen below. 4. I possible, hose assemblies have to be protected against damage caused by external mechanical, thermal, or chemical inluences. 5. Varnishing hose assemblies should be avoided since the outer hose layer may be impaired in its properties o use due to reactions with varnish and the detectability o the marking and possible cracks may be prevented. Hose assemblies should be protected prior to varnishing the machine parts by masking off or a film cover. 6. Possibly present saeguarding measures on the machine have to be re-attached upon installation o the hose assemblies, e. g. saeguarding covers. The initial protected installation position has to be restored. The rule „Hydraulic hose assemblies” (BGR 237) or DIN 20066 “Hydraulic luid power - Hose assemblies - dimensions, requirements” provides an overview o essential installation criteria.

Note When installing hose assemblies, it is imperative to observe the installation instructions o the hose manuacturer, e g. minimum bending radii.

Fig. 15

Hose assemblies in natural position on a test cell 37


4.3.5

Regular check o hose assemblies Due to ageing, wear and tear, and damage the hose assemblies have to be checked on a regular basis. For this, the hose assemblies have to be checked or external deficiencies (visually) by an authorized person (see also TRBS 1203 „Beähigte Person”) at least once a year; see also rule „Hydraulic hose assemblies” (BGR 237). I the manuacturer makes concrete provisions regarding the aorementioned, these have to be observed. Further notices regarding authorized persons (formerly known as technical experts), tests, and test intervals, see section 7. These tests have to be documented together with the date in a test log, e. g. when testing the machine (see also TRBS 1201 „Prüungen” (Checking)). The test criteria are: • leakages on the hose, the hose assembly, or the fitting, • the hose coming out o the fitting, • damage or deormations to fittings reducing the unctionality and strength o the fittings or o the connection fitting-hose, • damage o the external layer up to the insert (scour marks, cuts, cracks), • embrittlement o the external layer (ormation o cracks in the hose material), • deormations not corresponding to the natural shape o the hose assembly, in pressurized or depressurized condition or when being bent, e. g. layer separation, ormation o bubbles, pinch points, knees, • corrosion o the fitting reducing the unctionality and the strength, • Can the hose assemblies still move reely or are there pinch, shear, or scour points caused by attaching new parts o the system or power units? • Is it ensured that hose assemblies do not project into traffic paths, even when the power units connected via hose assemblies are driven to their respective end positions? • Have hose assemblies been varnished (explanation: cracks and labeling cannot be seen!)? • Have the storage periods and the lietime been exceeded? • Have all covers been re-mounted afer the test? • Are additional stripping protections provided or are they required?

38


Note Hose assemblies have to be checked at regular intervals. Hose assemblies shall not be patted by hands when being checked

4.3.6

Faulty hose assemblies I deficiencies regarding the sae condition o a hose assembly are detected during the test, the relevant hose assembly has to be replaced. Figure 16 shows some aulty hydraulic hose assemblies. Hose assemblies must not be repaired and must not be assembled rom old parts.

Fig. 16 Examples o ailed hydraulic hose assemblies

I several hose assemblies are replaced simultaneously, it has to be ensured that the connections cannot be conused, e. g. by marking them.

39


Note Faulty hose assemblies have to be replaced immediately!

4.3.7

Lietime o hose assemblies

Basically, hoses and hose assemblies are subject to a natural ageing process even i they are stored properly (according to section 4.6.2 o BGR 237) and operated under admissible loads. This ageing process reduces the perormance o the hose assemblies. Thus, the lietime o a hose assembly is limited. The possible lietime (i.e. period o use) o hose assemblies especially depends on the operation and environmental conditions. Due to the wide range o applications or hose assemblies, it is thus not possible or technical reasons to speciy a binding, maximum admissible lietime in saety rules and regulations and standards. The instructions o the hose and hose assembly manuacturers regarding the maximum storage time have to be observed. When producing the hose assembly, the hose should not be older than our years. When determining the lietime or the corresponding hose assemblies used on a machine, the user first and oremost has to base his decision on the replacement intervals recommended by the machine manuacturer, but also on his own experience regarding his individual operating conditions. This especially holds true when the lietime recommended by the manuacturer is exceeded. Prolonging the lietime is possible i • corresponding test values and experience on part o the machine manuacturer, the operator or the hose and hose assembly manuacturers are available, • a risk assessment has been conducted and documented by the operator that considered secondary saeguarding measures against hazards caused by hose assembly ailures as well, and • the test or sae condition is carried out at appropriate and fixed intervals and by an authorized person.

40


For the recurring test it should be clarified i the preconditions that lead to the determination o a certain lietime have changed, e. g. higher system pressures, changed location o installation. In this case, a risk assessment has to be carried out. It is absolutely recommendable to shorten the test intervals, e. g. to biannually or quarterly (instead o at least annually), when prolonging the lietime. Unless there are other specifications regarding the lietime o hydraulic hose assemblies, six years are recommended as reerence value, see also rule “Hydraulic hose assemblies” (BGR 237).

4.3.8

Securing the environment in case o hose assembly ailures In general, hose assemblies perorm their task without any problems when they are designed and selected properly, produced careully, and installed correctly. However, it has to be considered that ailures o hose assemblies, e. g. near work stations and traffic paths, can lead to hazards, e. g.: • leakage o hydraulic luid at high pressure, • lashing, and • fire hazard. Thus, additional measures or saeguarding the environment in case o hose assembly ailures have to be taken at those points, e. g. by means o additional stripping protection or screening (see figure 17).

Fig. 17 Stripping protection on hose assemblies 41


Special protective hoses or hydraulic hose assemblies can, i properly dimensioned and installed, contribute to a reduction o risks caused by ejected hydraulic luid jets. The protective hoses must not be closed on both ends in order not to impair their protective effect. The cross-section has to be sufficient. This makes the protective hose to unction as intended. Saeguarding measures against hose assembly ailures are not imperative i there is no hazard, e. g. by hose assemblies routed within machine enclosures.

4.3.9

Particularities o plastic hose assemblies Plastic hose assemblies are used more and more on machines with confined installation conditions, on mobile devices, and in the chemical industry. Some technological advantages o the plastic hose assemblies can be: • 20 to 30% weight reduction, • reduced external diameter and minimum bending radius, • higher milling and abrasion resistance, • good resistance against diverse chemical substances, as well as • low sensitivity regarding water-containing cooling lubricants, • no or only low inluence o ageing during storage time beore use, • relatively low price, especially or small nominal widths. Some technological disadvantages o the plastic hose assemblies can be: • higher breathing volume, • higher loss o elasticity afer longer periods o use, • lower torsional strength, thus twisting possible during installation, • higher sensitivity regarding mechanical damage, especially i pressure carriers consist o plastic yarn meshwork, • higher sensitivity regarding UV radiation, thermal radiation, and liquid metal, e. g. welding beads, • higher sensitivity o the external layer regarding cutting oils (however, depending strongly on the material). The above mentioned advantages and disadvantages o plastic hose assemblies have to be taken into consideration during design, selection, and installation. Regarding lietime, replacement, and installation, section 4.3.7 applies.

42


Possible exclusions regarding the use on the part o the manuacturers have to be observed.

4.4

Hydraulic cylinders Beore starting to replace hydraulic cylinders, these have to be ree o all orces, e. g. caused by elevated loads. Furthermore, it has to be paid attention to the act that depressurization is implemented on both the piston and the rod side ( see figure 18). The technical data o replacement cylinders have to comply with those o the types to be replaced. In order to prevent unoreseeable sudden parts movements caused by residual air in the cylinders, these have to be filled with hydraulic luid and vented by several extracting and retracting procedures in idle in the service workshop or via the system hydraulics beore they are installed. I this is not implemented automatically, the ventilation has to be implemented manually on the piston and rod side. In doing so, possibly existing bleeding screws have to be used. The fittings must only be re-tightened when the leaking oil is ree o bubbles. I sealing plugs are used afer the hydraulic cylinders have been filled, it is important to remove these beore installation. This is particularly important on the piston rod side, in order to avoid pressure transmissions. I travel sensors or proximity switches exist at the cylinders, the electrical cables have to be connected properly. I electrical cables run the danger o being conused, these have to be marked beore they are disconnected. Sealing sleeves o leaky hydraulic cylinders must be replaced in accordance with the provisions o the manuacturer only. When replacing the hydraulic cylinder, a possibly existing piston rod protection, e. g. sleeve or sheet metal cover, has to be re-installed afer installation.

43

Fig. 18 Hydraulic cylinder with pilot-operated check valve

Afer having replaced a cylinder o a clamping device in particular, the machine or the system must be approved or the operator afer sufficient test runs only. In order to attach cylinders, parts approved by the manuacturer must be used only (such as screws in the required property class). The details regarding thread design and screw-in length have to be observed. When working on parts o a hydraulic cylinder, including seals, cleanliness has to be top priority.

4.5

Pumps and hydraulic motors When replacing hydraulic pumps and motors, large quantities o hydraulic luid can leak out. In order to prevent the slip hazard, appropriate collection containers (see figure 19) have to be kept at hand. Connections and attachments o the depressurized hydro pump or the hydro motor have to be loosened in accordance with the manuacturer’s instructions. In order to avoid conusions, connections and lines have to be marked beore disconnecting them. Openings o lines and motor-side langes have to be protected against contaminations. Installing, filling, starting-up, venting, and adjusting hydraulic pumps and motors should be carried out in accordance with the manuacturer’s details in the operating instructions. The direction o rotation o the pump has to be observed during the

44

Fig. 19 Mobile hydraulic pump in an oil drip pan

installation procedure. When installing the electric motor, care must be taken to ensure the proper electric connection (rotating field). When assembling pump, suction line, and tank it has to be observed that the suction filter is installed properly. The saeguarding equipment has to be re-installed beore commissioning.

4.6

Valve blocks In order to prevent conusions, the individual connections o the valves or stacking assemblies o valve blocks have to be numbered respectively marked beore being disassembled (see figure 20). Valves must be installed and demounted exerting the utmost care and cleanliness only. During the installation, the O-ring sealing elements within valve stacking assemblies have to be checked or proper seat. Deective seal elements must be replaced immediately. All technical data (including wiring symbols and settings) o replacement valves have to comply with the provisions o the manuacturer respectively with the data o the type to be replaced.

45

Fig. 20 Marking hydraulic valve blocks

The valves/valve blocks have to be assembled observing the order o the stacking assembly. In doing so, the installation position specified by the manuacturer has to be observed. The selected attachment screws have to comply with the dimensions and strength classes specified in the valve data sheet. The screws have to be tightened evenly and exactly to the torque specified in the valve data sheet as well. When replacing aulty switching solenoids on valves, the required voltages and perormance details have to be observed. Solenoids or 24 Volts operation do not execute the switching unction when operated with 12 Volts or example. When installing replacement valves o other manuacturers, the electric pin assignments o the connection plugs have to be observed. These can be ound in the related valve data sheet.

46


4.7

Accumulator systems Accumulators are devices the manuacturer has to meet special saety provisions or. Furthermore, the operator o work equipment has to observe the provisions or the tests in accordance with the Ordinance on Industrial Saety and Health (see section 7). As maintaining and filling accumulators with gas, measuring pressures, and testing upon commissioning require special knowledge, work on accumulator systems must only be conducted by especially trained maintenance technicians or by the manuacturer. It is imperative to observe the provisions o the manuacturer in the operating instructions. Beore working on the accumulator the pressure in the accumulator has to be reduced, along with the pressure o the system hydraulics. This is implemented either automatically or via a manual pressure reduction eature at the accumulator saety block. A pressure indicator, e. g. pressure gauge, has to be used to check the efficiency o the depressurization procedure. It has to be observed that the accumulator may be under high pressure on the gas side. It may be required to reduce this pressure as well. Beore the accumulator is removed rom the system, both, the luid and the gas side must be ully unloaded. New or repaired accumulators on oil-hydraulic systems may be delivered precharged with nitrogen (at low pressure o, e. g.. 2 bar) on the gas side in order to protect the accumulator bladder against in-transit damage. Beore commissioning, these accumulators have to be charged to the charging pressure specified in the hydraulic circuit diagram using nitrogen.

Note Due to risk o explosion, in no case may oxygen or air be used to fill accumulators.

When replacing the gas-side filling valve in the accumulator, valves specified by the manuacturer (only genuine spare parts) may be used only. 47


Fig. 21 Warning note on accumulator system

It is imperative to observe the notices in the operating instructions or filling the accumulator with nitrogen. The accumulator filling device comprises • pressure reducing valve, connection line rom the gas bottle/central gas supply to the accumulator with corresponding connections, • accumulator-side port with pressure gauge, • appropriate tools. Neither welding nor soldering works and no mechanic processing may be implemented on accumulators. On the basis o the special saety-relevance, accumulators have to be checked or mechanical damage. Afer installation o the accumulator, the accumulator saety block has to be attached correctly and the accumulator (see figure 22) and possibly existing protective guards against external damage have to be re-installed properly.

4.8

Filters Filtering the hydraulic luid in a reliable manner is an imperative precondition or trouble-ree unction and long lietimes o all hydraulic components and thus o the overall machine or system.

48

Fig.22 Hydraulic accumulator

Fig. 23 Hydraulic filter with clogging indicator

Filters have to be checked on a regular basis and replaced in accordance with the maintenance scheme or the clogging indicator. Figure 23 shows a filter unit with clogging indicator.

Note The check and replacement intervals o the filter systems have to be observed!

When changing filters, the pressure reduction, the risk o scalding by hot hydraulic oil, the prevention o dirt and water entering the system, the condition o seals and system bleeding must be observed. In case additional filters are installed at a later point in time, these have to be installed in an easily to be maintained manner outside o the danger areas and must meet the requirements o DIN EN ISO 4413 (e. g.. clogging indicator).

49


Fig. 24 Hydraulic power unit on stationary production acility 50

5

Working on machines and systems

5.1

General Basically, the manuacturer’s provisions in the operating instructions have to be observed. Along with the basic general saety instructions or maintenance work and or handling hydraulic components (see section 4), the ollowing section contains urther notices or the sae hydraulic maintenance on stationary machines and systems (see figure 24).

5.1.1

Reducing hydraulic energy Beore starting to work, the hydraulic energy in the system has to be reduced. Re-closing o the system has to be prevented. I individual hydraulic circuits o the hydraulic system are separated rom the common pressure supply, it has to be checked i the correct connection has been disconnected. Furthermore, the accumulators connected to the hydraulic system have to be disconnected rom the system or depressurized (see figure 25). The depressurization must not lead to new hazards, e. g. loosening o clamping devices. The complete pressure reduction has to be checked (see “five-finger rule” in section 1.5).

Fig. 25 Depressurized hydraulic accumulators with closed pressure lines 51


Despite the energy supply being switched off, hydraulically elevated loads, e. g. machine parts, work platorms, hydraulic vertical axes, cause a substantial pressure in parts o the hydraulic system. On more complex machines and systems, this pressure can transer to urther parts o the system. Thus, elevated loads, e. g. material to be conveyed or machine parts, have to be lowered, secured using existing locks, or supported in a sae manner beore starting the maintenance work. Afer reduction o all pressures supplied into the hydraulic system, it is possible that residual pressures still exist in trapped heads o luid between valves and other parts. These have to be reduced as well, e. g. by operating the valves several times or in accordance with the manuacturer’s provisions. The opening o the screwed connections on hydraulic lines should proceed at first slowly and careully afer the depressurization took place. The urther loosening o the screwed connections should be done careully as well, in order to realize possible hazards caused by the still existing pressure o the hydraulic luid in time (slightly knocking on the screwed connection is helpul) and to take protective measures. I pressure is still present, the screwed connection must not be loosened urther. The depressurization in the system has to be repeated and the effects o this procedure have to be re-checked.

5.1.2

Re-commissioning Upon completion o troubleshooting and correction o aults the connections and parts have to be checked or compliance with the specifications o the circuit diagram. All loosened screws, line connections (see figure 26), and electric plug-andsocket connections have to be tightened and checked. Afer completion o maintenance work, it must be observed that tank lines be reopened, i they were closed beore. The ollowing measures have to be taken to prevent hazards caused by possibly occurring machine malunctions afer completion o the repair work: • protective guards have to be brought to their protective position or activated, • protection by means o distance.

52

Fig. 26 Markings on pipe and hose side

Afer completion o the maintenance or repair work on the hydraulic parts these have to be filled and vented. The running-in and adjusting specifications have to be observed or the pumps in particular. Hydraulic pumps mostly are sel-priming. Adjustment work on the pressure relie valves must only be conducted by the manuacturer or in accordance with the manuacturer’s specifications, e. g. according to the pressure measurement sheets. It is imperative to adhere to the sequence o the procedure contained therein. Incomplete venting procedures may lead to ailures and hazards in machines and systems caused by suddenly starting movements. Venting the system completely prevents unoreseeable sudden movements o hydraulic cylinders and motors, e. g. stick slip. Afer bleeding o the hydraulic system, all hydraulic unctions have to be checked. In doing so, the specifications regarding saety have to be observed, e. g. reduced system pressure, screenings. When testing the hydraulic unctions, it is important to keep sufficient distance as regards to reaching danger areas. It has to be e nsured that neither the maintenance technician nor other persons stay below elevated loads or in danger areas. All unctions o cylinders have to be tested separately, i possible, at reduced speed and without loads. Supports and saety measures or elevated loads must be removed only when the load is held saely by the hydraulic system again.

53


5.2

Working on machine tools

5.2.1

Clamping cylinders Machine tools may have hydraulic clamping devices, the structure o which can be very complex in some cases (see figure 27). These clamping devices can clamp “a ctively” by hydraulic pressure and be supported by a hydraulic accumulator or they operate according to the closed circuit current principle and generate the clamping orce by spring tensioning. For releasing the clamped parts in the case o the closed circuit principle, spring tensioning is overcome through the use o a hydraulic cylinder. With this unctional principle sudden pressure drops, e. g. due to hydraulic line ailure, or a deadlock o the clamping system loosening suddenly as a result o the spring orce can lead to pinch hazards or operators and maintenance technicians.

5.2.2

Vertical slides on machine tools Machine tools may have hydraulically elevated vertical axes or other axes loaded by gravity that are held in their position by means o hydraulic brake and holding devices. These vertical slides have to be considered alike the elevated loads (see section 5.1.1).

Fig. 27 Complex clamping module o a transer line 54


5.3

Working on hydraulic presses In accordance with the European Machinery Directive presses are classified as particularly dangerous machines. Thus, press manuacturers have to equip the machines with comprehensive saety technology. On the basis o this comprehensive saety technology the maintenance technicians or hydraulic systems have to amiliarize with the particularities o these machines beore starting any maintenance work. Beore starting any maintenance work the drive has to be switched off and an existing turn-off device has to be operated. When working on hydraulic presses below elevated loads, e. g. upper die, the device has to be brought into the protection position against retraction o the slide at first. Normally, such devices are installed on presses with a bolster plate depth o more than 800 mm and a stroke o more than 500 mm. I the press is not equipped with such a device a support (see figure 28) has to be used that is able to accept the orces present when the drive is switched off. Notices to the aorementioned can also be ound in section 3.6 o chapter 2.3 (Presses in metal processing) o the rule „Operating work equipment” (BGR/GUV-R 500).

Fig. 28 Slide support on a hydraulic press 55


5.4

Working on hydraulic scissors lifs Industrial and mobile hydraulic scissors lifs, lifing tables, and lifing platorms are equipped with maintenance supports. When conducting work on the hydraulic system that cannot be carried out with the platorm lowered completely the maintenance support (see figure 29) has to be used. From the engineering point o view this support is designed in a way that it is able to accept all weight orces o the parts in a sae manner and in doing so is secured against slipping. This is to prevent improvised measures, e. g. with squared timbers or the same. When installing and removing the maintenance support it has to be ensured that the elevated work platorm is held saely by hydraulic means or with appropriate load-carrying equipment.

Fig. 29 Installed maintenance support on hydraulic scissors lif 56

6

Working on the mobile hydraulic system

Along with the general saety instructions regarding maintenance work and handling the hydraulic components (see section 4) the ollowing sections have to be considered in addition to the manuacturer’s specifications in the operating instructions (including maintenance and repair instructions) when maintaining the mobile hydraulic system.

6.1

General In addition to the notices described already or the hydraulic system o stationary machines (see section 5.1) urther aspects have to be taken into consideration or mobile hydraulic work equipment. Maintenance work is ofen conducted outside workshops, e. g. or sel-propelled machines used on construction sites or off roads. In doing so, tools and aids are ofen available to a limited extent only. Different operating pressure levels have to be observed or implementing maintenance work. These start with approximately 60 bar or low pressure hydraulic systems or arm and harvesting machines and range up to pressures o over 400 bar or earth-moving machines.

6.1.1

Securing the vehicle In principle, vehicles should be positioned on firm ground when conducting maintenance work. This especially holds true or maintenance work on vehicles that can tilt or swivel attachments or superstructures, e. g. booms, hydraulically tiltable cabs, conveyor belts. Beore starting to work on the hydraulic system, the vehicles have to be secured against: • rolling due to uneven ground, • rolling due to orce effect caused by the maintenance work, • tilting caused by changes to the position o the center o gravity (also when working with hoisting platorms). Elevated parts or superstructures o vehicles have to be lowered to the ground, e. g. loading device, boom, or the required mechanical locks such as locking pins, cylinder support, and the same have to be used. Furthermore, all required locks have to be put in place, e. g. articulated steering lock or vehicles with articulated steering (see figure 30). 57

Fig. 30 Installed articulated steering lock

The support areas or possibly extracted supports have to be able to accept the present orces. For drive-on platorms the wheels have to be secured by means o stop-blocks. When positioning the vehicles on column lifs with small centered platorm the vehicle has to be lashed to the platorm or wired (see figure 35).

Note Vehicles must not be accessed in lifed condition.

6.1.2

58

Depressurizing Beore starting any work the ollowing has to be conducted: • mobile hydraulic systems have to be depressurized, • vehicle drives have to be switched off, • hydraulic systems have to be switched off, • hydraulic accumulators have to be closed on the pressure side and depressurized.

Fig. 31 Oil collection pan

Note: Caution with residual pressures caused by trapped fluid volumes, e. g. between valves and cylinders. These have to be depressurized by operating the control lever or the valve. The depressurization has to be checked, e. g. by means of a pressure gauge.

6.1.3

Collection container When disassembling hydraulic components, drip pans o suitable shape and size (see figure 31) have to be positioned below the corresponding parts in order to collect possible leaking quantities o residual oil.

6.1.4

Hose assemblies Connections and attachments have to be loosened in accordance with the specifications o the manuacturer (see sections 4.2 and 4.3). I there is the danger o conusing the connections o the lines in the confined space o the vehicle (see figure 32), these have to be marked beore being loosened or removed.

Fig. 32 Hose assemblies on a mobile hydraulic system

59

Fig. 33 Support rame when working on wheel-type loaders

Beore replacing hose assemblies the depressurization o the mobile hydraulic system has to be checked in any case. Damaged hose assemblies have to be removed wearing protective gloves as projecting metal wires rom the meshwork pose a risk o injury. Frequently changed attachments such as adjustment devices o the orks or swiveling devices mostly are equipped with quick couplers sealing both connection parts (attachment and line side) automatically afer the line has been interrupted. When changing over to quick couplers, the specifications o the manuacturer have to be observed.

6.1.5

Disassembling heavy parts Substantial orces can be present on the lifing cylinders o the vehicle superstructures. Beore working on cylinders, these orces have to be accepted, e. g. by lowering the attachments or superstructures. I mechanical blocking by means o a bolt locking mechanism is not provided, the use o support rames is recommended (see figure 33). Numerous hydraulic components, e. g. traction drives, main pumps, boom cylinders, are characterized by high dead loads and off-center position o the center o gravity. Thus, replacing these components has to be conducted with the help o lifing gear attached to the designed attachment points.

6.1.6

60

Replacing the hydraulic luid Mobile suction devices used to empty the tank are suitable or replacing the hydraulic luid (see figure 34). Replaced filters can drain with the help o a hopper device.

Fig. 34 Aid to dispose o old hydraulic oil

Mobile filling devices with integrated leakage protection/collection pan are particularly suitable or filling the system with new hydraulic oil. When changing the hydraulic luid, care must be taken that no contamination enters the tank or other parts o the hydraulic circuit. To achieve the desired cleanliness class, also reshly supplied hydraulic luid must be filtered.

6.1.7

Fire hazards Hydraulic luid may ignite at hot suraces, e. g. exhaust maniold, turbochargers. Insulating materials have a wicking unction when contaminated with hydraulic luid, which makes them easily inlammable. Measures or reducing the fire hazard are: • removing leaked hydraulic luid completely (see section 2.2) and wiping parts dry, • renewing soaked insulation material, e. g. noise protection lining, • avoiding external ignition sources, e. g. cigarettes, • covering hot suraces.

6.1.8

Working while drive is running Basically, repair work must only be carried out with the drive standing still. I work can only be conducted with the drive running, e. g. or testing and adjustment work, hazards have to be taken into account caused by: • unprotected mechanical drives with rotating parts, • hot suraces o parts, • noise. The work must only be conducted by trained and experienced maintenance technicians. When conducting these works corresponding technical and personal 61


protective measures have to be taken, e. g. saety by means o distance, covers, hearing protection, and urther personal protective equipment, i required.

6.1.9

Re-commissioning Afer completion o the maintenance work, including the ready-to-operate filling and venting o the hydraulic system, the drive and work unctions have to be tested individually and i possible at low speeds and load-ree. This should be carried out either behind screenings or rom the sae distance. The ollowing procedure is recommended or testing the unctionality o the hydraulic system: 1. checking all valve unctions or correct sense o direction and shut-down unction (neutral position), 2. executing larger travels o cylinders or swiveling areas o motors. While testing the unctionality o the hydraulic system, the machine operator has to ensure that no persons stay in the danger area. For urther notices, see section 5.1.2.

6.1.10

Spare parts Specifications or approvals o the manuacturer have to be complied with, e. g. regarding spare parts or hydraulic systems, hose assemblies, material specifications, hydraulic luids, and the like.

Note The operating instructions (including maintenance and repair instructions), as well as the spare parts list have to be carried along or kept at hand on site in order to implement maintenance work on mobile hydraulic systems!

62


6.2

Working on industrial trucks

6.2.1

General Depending on the type and extent o repair works on mobile hydraulic systems o industrial trucks, this work is conducted by internal operating departments, mobile maintenance services, or at service locations o the manuacturers or dealers.

Fig. 35 Lifing orks removed or working on the hydraulic system o a ork-lif truck

In industrial trucks mobile hydraulic systems are used or • the traction drive, • the lifing rame with tilting device, • the adjustment device or ork-lif orks or the pivoting device, • the power-assisted steering system. I maintenance work on industrial trucks poses hazards caused by possibly bumping against the ork-lif orks, e. g. in the area o traffic paths, the orks have to be removed beore starting any works. This also applies to the lifing o the industrial truck using a hoisting platorm.

63

Fig. 36 Lashed lifing rame when working on tilting cylinders

6.2.2

Traction drive I replacing the traction drive hydraulic motor requires the lifing rame to be lifed, the rame has to be secured against lowering in accordance with the manuacturer’s specification.

6.2.3

Lifing cylinder The sae condition o the lifing rame is essential or the operational saety o the industrial truck. Repairs should only be conducted by especially trained personnel, e. g. with the manuacturer, or by the customer service. The manuacturer’s specifications have to be observed during all works on the lifing rame. Beore starting any works on lifing cylinders, the lifing rame has to be lowered, supported, driven into a rame, or blocked mechanically. Working on telescopable lifing rames, e. g. in duplex or triplex design, should be lef to the customer service. When installing a new lifing cylinder, it has to be observed that the hydraulic hose assemblies are inserted properly into the designed guiding/delection pulleys. On older industrial trucks with hose rollers at the side o the lifing rame it has to be observed that the hose assembly is subject to spring orce on the roller side. When loosening the connection, the hose assembly has to be secured against whipping, e. g. by means o a second person. In doing so, the hazard o being pulled-in or pinched has to be observed at the hose roller.

6.2.4

Tilting cylinder Beore starting to work on the tilting cylinders, the lifing rame has to be secured against moving due to its dead load in accordance with the manuacturer’s specifications. This is done or example by lashing the lifing gear in the rearmost position using the designed attachment points or on the driver protection roo (see figure 36). The tilting cylinders have to be filled with hydraulic luid beore being installed (see section 4.4).

64

Fig. 37 Saety support on an hydraulically elevated vehicle superstructure

6.2.5

Power-assisted steering As the installation space o the steering axis unit below the industrial trucks is very narrow, it seems to be advisable to disassemble the complete steering axis unit when working on the steering hydraulic system. The disassembly has to be carried out in accordance with the manuacturer’s instructions. I there are accumulators in the hydraulic circuit o the steering system, these have to be depressurized beore starting any works.

6.3

Working on hydraulically driven vehicle attachments and superstructures and vehicle cranes

6.3.1

General As vehicle attachments or superstructures are ofen characterized by high weights, e. g. derrick booms, cranes, swivel towers, and due to the inluence o gusts o winds during maintenance works in open territory, these attachments and superstructures pose a huge hazard when lifed. Furthermore, it has to be observed that trapped pressures could exist due to hydraulically elevated loads. Basically, elevated loads have to be lowered or supported in a sae manner (see figures 37 and 38). The system must be depressurized and the depressurized condition must Fig. 38 Boom o a concrete pump lowered to the ground


be checked. Further notes on maintenance work on vehicles can also be ound in section 5.9.3 o the rule „Vehicle maintenance“ (BGR/GUV-R 157). Attachments, swivel towers, derrick booms, or the like that are not affected by the repair works, should be moved out o the work area beore starting any works.

6.3.2

Vehicle main pumps Vehicle main pumps are characterized by high masses and can be removed more easily using lifing gear. Pumps installed below the vehicle can be positioned on the workshop loor, hand orklif truck or cavity cover below the vehicle with the help o lifing gear (see figure 39). The cavity cover has to have the corresponding load-carrying capacity.

Fig. 39 Vehicle main pump on a load lifing device

6.3.3

66

Protecting accumulator and hose assemblies I there is the danger o mechanical damage to installed accumulators or hydraulic hose assemblies during the maintenance work, these have to be removed or screened or the time o the maintenance work.


6.3.4

Replacing cylinders When disassembling hydraulic cylinders, there must be no external orces on the support points (piston rod and cylinder bottom side). Thus, the booms have to be supported completely or positioned on the loor. Hydraulic cylinders may be pressurized – even i the load has been lowered. This pressure has to be reduced via the corresponding check valves (piloted check valve) on bottom and rod side or by loosening the fittings careully beore disassembly. It is reasonable to fill the new cylinders to be installed with hydraulic luid beorehand and to vent these (see section 4.4).

6.3.5

Checking the hose assemblies When conducting annual vehicle checks (according to § 57 o the accident prevention regulation “Vehicles” [BGV D29]) or when checking the attachments or superstructures, the hydraulic hose assemblies have to be checked as well (see section 4.3.5).

6.4

Working on earth-moving equipment and other automotive machines

6.4.1

General The individual parts o the work equipment and the chassis o earth-moving machines, as well as other automobile machines may be characterized by high dead loads. Along with present oil pressure, accumulators are used requently posing a particular risk potential (see section 4.7). Earth moving machines requently are repaired, serviced and maintained in rough terrain or on construction sites. Sudden position changes o the machine or its parts, as well as the risk o alling down when being on higher parts o machines while implementing maintenance work cause particular hazards (see section 6.4.3).

67


6.4.2

Securing machines and machine parts against movement

Beore starting any maintenance work, the machine has to be driven onto level territory with firm ground and has to be secured against rolling. The work equipment is to be lowered. I the maintenance work cannot be carried out on level territory, i work has to be done on the braking system, or i the machine has to be jacked up on one side, an additional saeguarding measure by means o stop-blocks is required. I machines are lifed or maintenance work, the machines have to be supported by means o bearing rames or with cross stacks consisting o boards or square timbers beore starting any work. Work on lifed machines or devices that are only held by the hydraulic pressure o the machine or the vehicle are inadmissible. By lifing a machine with articulated steering on one side or due to a loss o pressure in the hydraulic system, the steering system could be activated suddenly. In this, the machine may loose its stability and persons standing near the machine could be wedged. I works have to be implemented in the area o the articulated steering system or i machines having an articulated steering system have to be jacked up, the mechanical articulated steering lock (positive locking fixing device) has to be engaged first.

Fig. 40 Swivel lock on a hydraulic excavator in locked position 68

When working on hydraulic excavators, the superstructure has to be secured against swiveling beore starting any maintenance work (see figure 40). Furthermore, it has to be observed that hydraulic excavators and loaders are equipped with counterweights. I heavy parts have to be disassembled, the machine could tilt on the basis o the changed center o gravity. Work equipment has to be secured against moving by placing it on the ground, supporting it, or equivalent measures beore starting any work. I work has to be conducted below the lifed work equipment, the same has to be secured against lowering by means o the designed positive fitting supporting devices (see figure 41).

Fig. 41 Supporting device in place on an earth-moving machine

I there are no such saeguarding measures, the corresponding part has to be supported by means o bearing rames having sufficient load-carrying capacity. Stacking construction materials is not suitable to this end as these materials could lose their stability in case o impulsive stress when mounting the part.

6.4.3

High-level places o work It has to be possible to reach platorms or maintenance and repair work in a sae manner. I there is the risk o alling down, appropriate saeguarding equipment has to be used. Hydraulic components must not be used as climbing aids or attachment point or saeguarding equipment against alling.

69


Parts o the machine must only be used as place o work or access i the manuacturer has designed them to this end and i they are stable and skid-proo. I mounting work on site is conducted with the help o other work machines or industrial trucks, these have to be approved or these purposes and have to be equipped with an admissible device or accommodating persons, e. g. work platorm; see inormation “Work platorms on hydraulic excavators and loaders “(BGI 872). Works must not be carried out rom lifed work equipment, e. g. shovel or ork/pallet.

6.4.4

Depressurizing Beore starting to work, the pressure in the hydraulic system has to be reduced. This has to be implemented in accordance with the manuacturer’s specifications. Normally, accumulators are used in the steering, braking or hydraulic pilot control systems o machines, as well as in the work hydraulic circuits o loaders/loading machines as vibration dampening system. These have to be depressurized on the luid side beore starting any work. Note: If the accumulator of the hydraulic pilot control system has been depressurized already, the work equipment may only be lowered by means of a manual emergency lowering device by hand, e. g. via load holding valve on the boom of an hydraulic excavator.

Note Beore re-commissioning, load holding valves have to be re-adjusted in accordance with the manuacturer’s specifications!

The hydraulic tank on work machines can be under overpressure due to operating conditions. Beore starting any work on the hydraulic system the tank has to be depressurized.

70

Fig. 42 Shipboard crane on a pusher vessel

6.4.5

Disassembling parts It may be required to use lifing gear in order to carry out mounting work on hydraulic components. On construction sites this work is ofen are conducted with the help o other earth-moving machines. It has to be observed that the manuacturers designed and equipped these machines or lifing gear operation. The notices in the operating instructions have to be observed. During the mounting work, chain hoists may be o help allowing or positioning the parts precisely. Hydraulic cylinders have to be lifed by means o suitable lifing accessories, e. g. attached with lifing straps or round slings in two-stringed design. Extending o the piston rod during the lifing procedure can be prevented by closing the connections using blind plugs afer having disconnected the lines.

6.5

Working on water vehicles

6.5.1

General Diverse hydraulic equipment is operated on water vehicles. In this, the differentiation is made between hydraulic systems required or traction drive o a vessel, e. g. • rudder system, • wheel house lif, • maneuvering aids such as bow thrusters, articulation devices or the like, as well as • winches

71


and the machines installed on vessels and swimming devices (pontoon) or the most different applications, e. g. • dredgers, • rams, • cranes (see figure 42), • pump drives especially on tank vessels, • mobile hydraulic systems, as well as ramps, laps, and bulkhead closing devices. Due to the high orces required or the driving operation parts and superstructures to be moved on the vessels, the hydraulic equipment ofen is characterized by high dead loads. However, urther particularities as described in sections 6.5.2 to 6.5.5 have to be observed additionally.

6.5.2

Position change o the vessel Floating vessels never stop moving. Due to pull and wave effects o passing vessels, wind and swell (even in coastal waters), even vessels positioned in ports are subject to slight lateral tilting movements by several angular degrees. Loading and unloading reight vessels result in a constantly changing loating position around the longitudinal and transverse axes. The vessel movements can lead to unintended movements o unsecured vessel and machine parts. Thus, anticipatory planning o maintenance works on vessels is required.

Note All works have to be coordinated with the steerman.

6.5.3

72

Unsecured hydraulic drives on vessels For hydraulic systems o the driving operation, e. g. rudder systems, high requirements are posed regarding the availability and the operational saety o the systems. Within the sphere o action o these systems o the driving operation, saeguarding measures resulting in the rudder system being deactivated automatically are inadmissible rom the point o view o traffic law (see figure 43). Technical protective measures such as guards cannot be implemented in all positions. This poses

Fig. 43 Risks o pinching on a rudder system

the risk o accessing work and traffic areas, in which hydraulic parts are installed in an unprotected manner and stripping protections and pipe and hose rupture protections are requently missing. Due to the confined installation situation and possible stumble positions, there is a high risk o pinching and thus direct danger to lie due to moving system parts.

6.5.4

Limited installation conditions On the basis o the narrow installation situation in the hull and the metallic parts, interior walls, bulkheads, and doors on all sides most o the maintenance work is “work in confined spaces”, which is subject to special requirements regarding the electric equipment, see inormation “Working in confined spaces” (BGI 534).

6.5.5

Redundancy o important drive operation systems On the basis o vessel saety provisions, rudder systems are designed redundantly, i.e. in double design, in order to provide or high reliability and availability. This is to maintain the maneuverability even i the system has ailed. In doing so, different principles are applied: • wo parallel identical systems supplied by different energy sources with automatic switch-over, • separately engaged emergency systems with limited continuous operation o the rudder system (emergency manual rudder, electric auxiliary pump), • accumulators allowing or a limited number o rudder movements. Work on these systems must only be carried out afer consultation with the steerman! Beore starting any work on the hydraulic system, all relevant energy sources have to be turned off (see section 1.5). Even manual hydraulic rudder systems on small vessels and emergency manual pumps have to be secured against being used beore starting any maintenance work. 73

7

Required tests

7.1

General Work equipment (machines) has to be checked or a multitude o reasons. The regulations or the test are based on the Ordinance on Industrial Saety and Health. In order to ensure proper installation and sae unctionality o the work equipment, this has to be checked beore initial commissioning and afer every installation at a new location. The test has to be arranged by the operator o the work equipment (see also section 7.2). Furthermore, work equipment is subject to damaging inluences or wear and tear. In order to detect and remedy damages in a timely manner and to allow or sae operation, the work equipment has to be checked at regular intervals. These tests have to be arranged by the operator as well (see also section 7.3).

7.2

Checking or proper installation and sae unction When checking “or proper installation and sae unction”, criteria are assessed that relate to the installation or which can only be assessed on the completely installed machine. Some o these test criteria can already be assessed during a “visual inspection” in deactivated state, others require “unctional testing” with activated energ y supply. An overview over the recommended scope o a “visual inspection” (in connection with the hydraulic equipment) can be ound in Annex 1 letter C. An overview o the recommended scope o testing or a “unctional test” (in connection with the hydraulic equipment) can be ound in Annex 1 letter D.

7.3

Checking or sae provision and use Testing or sae provision and use assesses criteria which are subject to damaging inluences. However, this test has to be conducted afer accidents, modi fications

74

Required tests

(conversions) to the machine, longer terms o non-use, as well as afer repair measures as a result o damage (collision, act o God). A detailed overview over the recommended scope o testing or “sae provision and use” (in connection with the hydraulic equipment) can be ound in Annex E.

7.4

Legal bases or the tests The legal provisions or testing work equipment, (machines, systems and the like) can be ound in the Ordinance on Industrial Saety and Health. The operator o the work equipment himsel has to speciy test lists, as well as type and scope o the tests or his individual application conditions within the ramework o a risk assessment and has to implement the tests accordingly. Legal provisions and recommendations o the manuacturer have to be observed. Explanations in this context are contained in the technical rule on operational saety TRBS 1201 “Prüungen von Arbeitsmitteln und überwachungsbedürfigen Anlagen“ (Testing o work equipment and systems requiring monitoring). The test provisions o previous BG accident prevention provisions and saety rules still can be used to support the specification o the scope o testing and test intervals. The tests must only be implemented by authorized persons instructed by the employer. An authorized person in the meaning o the Ordinance on Industrial Saety and Health is a person who, on the basis o the vocational training, the proessional experience, and the contemporary proessional activity, has the expertise or testing work equipment, see technical rules or operational saety TRBS 1203 “Beähigte Person” (Authorized person)“. The rest results have to be documented and maintained in accordance with TRBS 1201.

75

8

First Aid

The first aid measures at the accident site are ofen decisive or the ollowing course o the healing procedure o an injury or even or saving the employee. In accordance with the accident prevention regulation „Basic principles o prevention” (BGV A1), the required number o trained first aiders has to be present in any case. The training is conducted by authorities approved by the institutions or statutory accident insurance and prevention. Furthermore, the employees have to be trained regarding the behavior in case o accidents at least once a year. In order to provide first aid as quickly and immediately as possible, the “reporting chain” has to be specified in a clear manner. • Who calls or help? • Where can help be called rom (location telephone, reporting authority)? • Which help is called (first aider, corporate reporting authority, public rescue service)? This is particularly problematic and thus important or maintenance works situated at a larger distance to other work places. In case o an accident, an emergency call to the corporate emergency authority or the rescue coordination center (or accidents in Germany -> call 112) has to be implemented as ollows: • Where • • • •

did it happen? happened? What How many injured/victims? type o injuries/illnesses? Which or queries! Wait

Working alone should be avoided in any case. In areas where implementing first aid measures is not possible or only to a limited extent, provisions or rescuing possibly injured have to be ensured. Places equipped with first aid kits or lushing devices have to be known and marked.

76

First Aid

The hazards occurred especially when handling hydraulic luids, as well as the corresponding first aid measures are: Hazard

Measure

Subcutaneous intrusion (injection) o hydraulic luids under high pressure

Consult doctor immediately ; very important: inorm doctor about course o accident (oil injection), otherwise small wounds could be overlooked or treated improperly!

Hydraulic luid in the eyes

Flush eyes at least 15 minutes with mild water (eye lushing device or clean water), contact doctor.

Swallowed hydraulic luids

Do not provoke vomiting, consult doctor immediately .

Burns due to hot hydraulic luid

Cover wound in sterile manner (i.e. with aseptic, non-adhesive dressing or material or burns); minor burns (hand and/or orearm can be cooled beore with mild water at least or 10 minutes; contact doctor.

Table: Measures in case o accidents with hydraulic luids

The rescue service/emergency doctor has to be inormed immediately on the type o hydraulic luid. The current saety data sheet or the operating instructions have to be held ready.

77

1 x e n n A 78

. y l e s i c e r p e r o ) m 0 . r 1 o r r n o e i e s r h t e v e , b h i r c c s s o e B d o t o t g s i n i p d r e t o s c t c a s r ” fi 1 e / h 0 T s . n r o u i c t c c o u r n t a s n c i s r g n o i r r t e a t r e n p e o r l e a ff i r d e  n e o G e d “ g u t i n i t s l u u y m b a e , s e r m t g e t i s n y t s o c o i l h u s e a l r d b y u h o r n T I (

g n i t o o h s e l b u o r T A

y c n h e i g u h q d e r o n  o a g t g i n p n i p m t r p u p a t o t  S s o . 9

r e d n i l y c g n i t s a o C . 7

r o r r E

e e r v g u t i n a s i s t r e e r p r a p e m x p E o e t . 5

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. 3

s e s i o n e v i s s e c x E . 1

n e h w s t c a p g m n i i e f n i h i L s . 8

d i u  l o  c g i l n i u r m a a d o y F h . 6

g w n l o i n s n o ) w u r o o w l t t o l o g  n o n i t y t n o r u n r e o i v p t u l o u r r n e O o ( d . 4

t e n s h e e t i c r t c o a ffi  u t s s n e n ) u i e i q ( e c r s r u t r s ffi o e s u d i v s n r e n a d r I p . 2

. n o i t a n i m a x e r e s o l c a o t t c e j b u s e r a s t n e n o p m o c l a u d i v i d n i e h t , d e n i m r e t e d n e e b s a h t l u a  e h t  o e r u t a n e h t n e h W

d i u l f c i l u a r d y H

e v l a v l o r t n o c w o l F

e s i o n e v i s s e c x E . 1

e n i l n r u t e R

o l o - s t u o o u c l r ) i h t a d e m e t m y e ffi v i t p w a i a o t d d d m e s l d l m n n e o a s n d a n i d o o c ( t o a e  s o o s t c d e i u i c d g d t a l i d e v e g i c s F w V h r i g e o l u t u e . o . i u i a e g l l u S t a l b h t F n d a c F . . . 1 2 3

s r e s l l n m e t s o o s e r a t e c t r e t s e n i g s b i i o t n y s a i v c c x r o t r n b e e r a e i l v d e v w r l l o b i o t o l a n h V a o t F V r t . . . 1 2 3

r e g s l e e n s d i t g s d n v l t o e fi n o u n e y l i t e l o n t l o i e e d n r r t i w e t c l o n l u o r e l u  v i l e o g e s a p l  l d p - m m n e n e n o s m i r v r g m e r s s e s p s t u t o u t g s o o p i o r o y c i e b e l o m n P m I C t S i R a R c . . . . . . 2 1 3 4 5 6

e d n ) e n e i t e l v v e i i n e r o t r n t p u c s c r d e d u l s s e l e u e o t l t r o e  a  z m p s e i e e e e e r e r v t k p m r d s d v m t d i p p r e i n n i u t c c . m p x o d e n o o l i  a d c o u e a d m - h a s e s g u e e P i e t n s ( v e e n d r c i i s d p s m u m o n o p s e t s p e t g a e n i f i n t e m e s r s a c m e n b t s c c o s o x u x o h u u r o i y e E P e B S s P P c V s N d . . . . . . . 2 . 8 1 3 4 5 6 7

r o n  d ) e t t t o o o e v r d l z i t m s e r a e e i n i c s m o i p n s e  e i b o i t k t t g o  o s m h e i t t c o p c e o l y o o v s n l o o n o m e a l d i l r - h r g r g g e a t o e r e i s d n e v o i v d n e r , i s ( ) n i n m p t p i i t . i t t o o n t l l h m r l p c g g n h l t n i n i r p p c u e e c p o e e u c u p u u a a p h  m  o b t t r t e o m o o t r v e u e o o s e o C A o O ( d P d W r N d m M C i C . . . . . . . . 8 1 2 3 4 5 6 7

, r r o g l t t e n l o ) e i c t m . a c r a o l m e a r r t (  y t n r a n t b c e e o u i o s v C s w V c y s i r . . 2 D 1

s e v l a v l o r t n o C

d s m w n e t e e r o a l v g s d u l i r s a i n y o o a s s v n l n o e e t r o r e w l r o e p  t p o e g o t n s a t m e o a o t e l s l d c i a o u p a d i c v h n m s e r r r d l g t i y t i e o t t c t r h s o b a t e l e i t u l n n u v a d o o t e l g e  i  o i r t t t n s k e c e o a i c t e v v w i e t h l  l r r t h o i e a e a a a l V d V e t F V S w C . . . . . . 2 1 3 4 5 6

s e v l a v e r u s s e r P

) g l e / e e i n b u d t p d e a t e y d i c a s n t r g r a s t g t n s o e n s o i e n l e p i e v i t n t r a t m v i b s e s  a i n a i e e u a l r t l n a t o  t v c e i n r c i g n a e n e o n ffi p u n v c r u m s w e r a v l r o n o h h r a a o o s u l u F w C c W n d ( V t w I . . . . . 1 2 3 4 5

e n i l e r u s s e r P

t e g n s i n d e o t s e y u n o t l m o l i n e h r o r t c o r c l e t v e a e e l t a l s t g p n o s m m p a i r s e t m e s s p s s o o o i p r o y c i m n P m I C t S i . . . . 1 2 3 4

s n o i t i d n o c n o i t c u S

y h l n g y i o k o h o r o o a o o t e t r l t r o t o o o r l n d o l e n e e d a i l n g e m g g w l n i g s o o o n o l l i o t o n c l o o c t c i r s o u t e c e e e d t t s p u o l i n i n n l s e n fi l l i y n n n e v n l e b e i l o o o l l c a i i i y l e i t t t d n v t i l r c a c c n a a l u t u u u a a m s V p S s S S m F i s . . . . e s . R a 1 2 3 4 5

79

s r e h t O

) e r u s s e r p t n e i c ffi u s n i ( s t u p t u o e h t n o s t n e m o m d n a s e c r o f t n e i c ffi u s n I . 2


t w e s h o g a i l s i g d o k a o e r h e o o e t l t w o m y s h y t t l o o i u g i t a o  s h i s  : s o t h o h d c d c e i g c s n o i s i u i n l o V a t V h a F . . . 1 2 3

s e s e v e g e l v p s i a s i t y t c e v o n t t  e l l l e e b o e r r h s d a t t g g i n u s i e n h o s o l v u c e r a s n r o o V U w P t W . . . o . l F 1 2 3 4

e

d e c e n n a g i t l i s g o h n r s g l e c i r u r h t e e t e i n o l o i R L t F . 1

. 2

e d e e s g n p v e w o i a y r l t t r k a r c p e a a e e o l o l l n e  p l e b e o t o t w a d i m l t e r t t i c s n y o u a n p t u u o t P r e e r m d e r c l t a s n u e u u r u a n d e I t U P R s o  . . . . 1 2 3 4

t r a p e v i r d . h c e M

80

e r u o l s r t n o r a s c e t n y e e t r i p n l o h u o c t s s r u o a t  n d i n s l i o a t r r e p e c r t s p n i n o r o d o  o e r l o o c I n m E c l . . 1 2

- d r s e n i o d o h i m t g t p e r y c o s t m a n e n l o i n y r e t t u a p i i l o u r a p h p d t  t u r s o i a t l g a r n r r  s n t o o o e l t o o e l w n r t y t o b o i - e r  o e o P s v b W o M K m . . . . . 1 2 3 4 5

) . l y e c , v r i r o D t o m (

e n e n c g i l o a r i a y  t ) k c r a e i c t a ) u t e n r e r v s  n l d e l o e g n l h i a w l a n a i g c e i n . s n r n r g r h ffi e e n a t . r t o e e n e u e d R w I n ( n o I t i ( . . . 1 2 3

s

e

d e e ) y s n c t g . l o a e l g ff u k a n d v o o . s a l a a r t k e l s n h  a o e a ( s c e l u i p o c v s n e d i t l i w s h t r t i l s a e o g o u a w n n o r i l g i o l s t t r o i s u s e r t n w h o o e e r s l t c e o t a r r n o o p r i o o n u e l o W o p p c n S I d t F t S C . . . . . 1

2 3

4

5

- w e d e s s g n n p e e e l o n a a r v r k r o e y t g l o c p k e n a a t a g o o o a l d e e a d r v n t l b r ) e t l b e t w i e e a e a o s a g g i t g r t n w a s n n a o t u r r r e i i n u i t t l v s e e s r e e m l r e s p u t u a a m a p n S o e n d e t V a t d S U ( o t r O s I . . . . P 1 . 2 3 4 5

e r e c e n n l t i a l t fi s e e r s e i s h d g r u g e i u e a r s k s s g s a e h o e g e n o e i o r l r L L t P c P . . . 1 2


3

n y o n y i k o t o l o a o o c i n n o e t e r s o u s t t l e c e e o d o t t r s a u r p l n r i n o n l i o t o o s e n fi l l i h o y n d n d n r e v t l n l g e b o i e i l o e o e o l l c h e o a i i i y n l l g g i t t t d n o v e t a g c a n i r c g a o m c o u m a l u w t o l u u a n a l l i o s t V l p S c s S c S s m F l i s e . . . . . e n 1 2 3 4 5 R i l

s r e h t O

) w o l f d n a e r u s s e r p n i s n o i t a i r a v ( s t n e m e v o m r o t o m d n a r e d n i l y c y k r e J . 3


e d , d e h a c t a o e o n  l v l . l a o g t l a l r n a . v i a ) a e e g t e r i b ( e o r c e r t i n n r u t a u r e e r l s ffi t e e s u p h u n t t ff e s u r g t u w n o o i I c a o l d p e r . 1

d i d d i u e l u l  t a  c n c i l i i l u m u d a a e r a t r d n d m y o y a o H c H  . . 1 2

e v n l o d i a t e v t c l a e r n o n i o r i d i t t n e m g a a o v t n t o c r n o - l a o r  w V c W o o . . l F 1 2

e

r

. . 2 1

. 3

c e e n l t n a i t fi l s s i e s h e n d r g g r u e r i a e u s h t k e s g g e a n o e o r l e i o P R L L t c

o s r l e d t l e o v s l i e n r t t t o l c l a i o r t ) o l n e e o  e s n V r t l p o c r r y e - s o R n b , l t d m t u c S o a t c , c s i u n s u p m r p V e t e a u P o c p t e  v o l s r m r m s p m M l u y u i u a n o e F p l P S e r p D ( P v u . . . . 1 2 3 4


n h e r i r s o c o o i t s ) t t t  t o , m u l c o o t e o s l o y l e l c l r n n e b e m e i r d g g e g m o a r b e e n n i i n r d v i v v r d t o i o i t p t i i t v t t t e g a l l c n p e r ( o c c p h n r s p p e n t e e t e u m s h o u u u  p j m  o r o o r  o o  t i e e e u o o d u o m o I a C C d M p l O s t d P d W o . . . . . . 2 . 1 3 4 5 6 7

) . l y c , r o t o m ( e v i r D

t i m c i s r l i a e h e l t d g h u a n i c i r e l h t d y ff c o w y e  o l o h t e  p o i l s b o n s o e n d r v e e o k i e l c t e t i c l e l t i a p o r S  s F s m . . 1 2


d s e n r e a d v g u i r s l n a i o w a s v n l o e n l e r o r e o w l o e p  t p r o o o t s t t e m n o l d a o s e e i c a g u p a d i c a d h s e r t n m r l l g t i y t i e o t t c t r h s o b a t v l e i u d o n n t l r u t l o  a r o i o g e e  m n s k y o t t e l a i c e t e t i r v v h w e t l u l a o r t i a a a e l a e t h s y V  V t F V S w C s . . . . . . 2 1 3 4 5 6


) e / e u d t p d e t a y e t d s o e r a s n o t v g e e i e n t l e l l e t n n e t m a v i b e e v i n a p n b u l l a t l c i t a  a t e i l v m i o n e o n ffi p u a t g u r t s v u r d s m o c l n n l n n n a i a o o s u U p l n d ( o U o V t w I c . . . . 1 2 3 4

e d y n e t l i n e l e t e e r v l u m p s e m s t s o e r y c n P S i . 1


o r t o r t o o o r l o n n d e l n e e e d a i l n p g e m i s w n l o g g o o g s l o n o d y l i o l t o l c l o o c t c i n a r t i u e o e c t e e t t s u r n i n b l i l a l s e n fi l l y l i v n p n a n n n e e i y a l l o o o m c y i e n i t s i t k t m d n v l o c c a c o i a u t s u e u o l a a r u o s t S l S t F i h V o S o s g . . . . . e i R h 1 2 3 4 5

81

) w o l f t n e i c ffi u s n i r o o n ( w o l s o o t g n i n n u r r o g n i n n u r t o n t u p t u O . 4

s r e h t O

. t r g e . h o i n c k y c e c t l ( i d e i ) r o . ) v ) r n i t s w e i t d s - n d t o g r c e t e p r s n d i c t l o e e i e l o h a e o m t l r i e t p r p l n c E l n r o l c p l . o a u : p n o - e u h a r r y y a s i t r m t c o g s r r t t n t r n n l n n s t l i u e p t n a l e g t u u t i o o i r e w c  p o a o a s p n S p s  S t ( c ( c i a . 1


t w e s h o g a i l s i g d o k a o e r h e o o e t l t w o m y s h y t t l o o i u g i t a o  s h i s  : s o t h o h d c d c e i g c s n o i s i u i n l o V a t V h a F . . . 1 2 3

s e v l a v l o r t n o c w o l F

r w e o o p e d d l y g e e o t g t e n o l g a t b a r n o i t a g ) l e t c w n o m s i i e a u t l v t w s t l n o e o n a o l s o F U ( t V c . . . 2 1 3

e

d e c e n n a g i t l i s g o h n r s g l e c i r u r h t e e t e i n o l o i R L t F . 1

s e d e g n v i a t k a r a a c e d d e e  n e p l e n t e a i d w d l m l y c l o u a t e e n n p t p r n r P r r u e e a m p t n e t u e u u e o v n d n I t P S r c i . . . 1 2 3


82

. 2

d n e e r s p i o n s o i t t g o m  i , m c o l y o t ) o u s l e a l l t p n e l r n m r g e r e i o r g e g g e a b e i n d v v v r i o t n n n i i o i t p b i i i t v t t t g a l o l l c n r e r ( c c p h n p r p p e u o e n t e e t o s h u p u u  o t m  o r o o r  o o  t i e e o m o o e u o o C i C C d M m l O s t d P d W o . . . . . . . 1 2 3 4 5 6 7

) . l y c , r o t o m ( e v i r D

. ) r . g a . e v e o g . e e w o ( e ( t ) e t d e e l n e ) g s c n o r a e e a e  i i r t c k k r c u c a d u i z o i r ffi n s  e i l l e l r b l y g a l n t e s a c i n e a i ( u n n n t r n n r h p o e r n d t e g t t t o u n i u s n n h O i I w R a I p . . . . 1 2 3 4


n a ) e l h u ff o g p o c r o t i n i n e h i h o c i u o t c t t s i s i d o o s w e t e s y g e n o l t a r c s p t l r o u k l e n e v o u n a a a a e t k t  c l o s a e s s i u p e s v d l l d s t l n s r e i n s a o e o o g p d n n a r l a i t r o u n . r i e g l e a w o n s o t r . n a o p o o o n e l e i W ( t S I w F S M p . . . . . . 1 2 3 4 5 6


t o t e - r a o o t s t  n t e ) o e e t i r S m ( w l s u e a o o s u t e e s d r n d p l r v n y o t l e n y r k a o e e t t g o o c a k e t c a p a e v l t t o l e e u e a m r g l a c  g p n l d e a b b i a n r n u t w a n s t d g i a w e o a o n a r l r e r i n r o u h v o r u e o r a s g l e q g l p o t e a d p n i n l e i o n O t I w V e S U t  S h . . . . . . 2 1 3 4 5 6

r

h e e t g l i n t i fi h l s s i e s o e e d o r g r a e u e s u k r t s g g s a e e e n c o s e i r n l e r L L a P c . . P 1 . 2 3


y o k o r a o o o o t l e t r t o r t o o o r l o n d e l n e e d a i l n n g e m i s w n l e g g o o g o p l n o l i o t o o c l o o c t c i y r t l s o u c l e e e d t t s u i n i n n l a l i s n fi l l t i e e v n r n n b a n e e i l o o o l c p i i y d e i t l t t n y n v l l c a c c i a u t s a a n u m u u a l s F i h V o S s S S m s g . . . . . e i R h 1 2 3 4 5

s r e h t O

e r u t a r e p m e t g n i t a r e p o e v i s s e c x E . 5

) m d g w e e n t l o l o l s l y a o t s s o o o t e i n t r h h h o t o c o t ( t  ) m g t e i i t t e i n n p s w h o y s e o h u n o i m i d u t t u s t o g r a l a n o r n u t i l p e l i o i n e h i u g r w e a t r c d o s  r i u n o n i i u e h t o a t n p i c n l p o i g a a i  d r e r e e w s  s n e r h l c s r p u o i h e s u i o l l e t l r e o t o l v d o  o c u l o a c t e t r m r o o y a r d r a v t e t e e a r t c t e u n a d y r p h e n e d t s ( y r e s a h i o e e w e u s w s t t m t h t n t o n d e a e r k  a t g a i n l a p o r p a o w t n w t e s i i e u t g s t i l g t r g n i g s o c o t n b n n o n e s s n n p i u i i i m o ffi l e u l i r o s k a c o l b u p t i o m p o o c s r e o i u o m o h o o m e s n n C d o M w A C T N C A D I e . . . . . . . . . 0 . 1 2 3 4 5 6 7 8 9 1

d i u l f e r u s s e r P

d o s o u s e o o t h o t o e t t w c m y y t d e i t l o n h a i o g  a i s n g s  o a a o : t h s d c k h c h i i g s i g s o l s w a i u i o l e h i V l V h e r o t F . . . 1 2 3

l o r t n s e o l c v a w v o l F

 e i o o l e o t p o t a r e t m s i e v i e u r v r u s p e h s ) e t ( i e v c s v v c e w l e l l  w o l o e u r a a e F l d m p v V d . . 1 2

e n i l n r u t e R

p m u P

s l d n a e o n d g i o s t n i e c a t c e g o e i c n r l c s r a u - w s o  t s s l s i s r e s s e u e o t n o r l i r h s L c o t t e r P fi . . 1 2

- l e l u o o w r o d t r t l  y n n  r o c r o o h c o c s g s n a d e y e i e t n p e i s c w l o m e h s u u p o o ffi a r e p S o L e o t F l t . . . 1 2 3

) . l y c , r o t o m ( e v i r D


y o c o n t ) e e n t i n g c i o i e a k ffi r t c c a e a i r ffi e  e  o w l e l l n s o a i s ( a n e t n r e s e r h e e s t g t s o u n i n s o L d I h I l . . . 2 3 1

h n g i o i h t a o l u n o o t c r h s i c e c i s s t s s w k o l e s c l t u e e o t s g r u l a s n o k s s e o a e e r o p L P d S . . . 2 1 3


e o p y t o o t e t o v w l n o a l o v i  t e t c n l e b e n a - ) t s a i s l l u s m a s o r h g r e i n c m P h U ( s . . 2 1


s s n u o h i t t s c d r e n e t s - a s l fi e s l c s l l a a e r d o r m n n e t u c s i o a s s s g i e t g c s e n o o i r l i o e r L t  r P c . . 1 2

83


d i u l f c i l u a r d y h g n i m a o F . 6

e n i l n r u t e R

84

e k a m e l b a t i u s n U . 1

l e r v e e p l o d i r u p l  i m e o v t o b e a u s d d t n c e e ff e g n n r l r i u t i t e w u R S o r . . 1 2

n l o i i t o c u w o s l n e o b s t l o p a e n e m s n u r l o i l P l s y i t o a l e u e s a g a l f  e k e a d h i a e v e S s L l . . 1 2



n g i s e y w d k o r a l i e o o l v e o t e r l n i l e s e r n v e l g o i n t d c i o u u l r S F W . . . 2 1 3

r e d n i l y c g n i t s a o C . 7

s y t a l y u l a e e  v t r l a a i o v d k e d c m e t d e a r e s m n o h i s r c i r a e d s m e p e t g h o a t l n c n i a r c t o h i e t c c p o t t w o n a i s t t s e w i o e S S m l i o . . i P d a b L . . 1 2

s e i t ) i . t l y n c a g r u n q i o t t e n o g a e v m k ( a t e n e l e i l v i c a r n ffi D r u e t s n n I I . . 1 2



w o l s o o t e t g a n k e a d e e m t t l a , s y n u i t j l d u m a  a a t g s e n d n i i i o i t o h n t c c e t l e n v i a l w o u a S S q V . . . 2 1 3

c i t s a l e d t o e o t n e s v e t n o i l n e s s e n o i H L . . 2 1

s r e h t O

g n i h c t i w s n e h w s k c o h s e n i L . 8




h c g i t n i s w s s  i m o : m s r a o r t e a t s l u p s m u e u s v e l c l c t a t a o v r r g o n F h t i . 1

d e m a o  d i u l  c i l u a r d y H . 1

d e g a m a d k s c e i u c q fi i o r o o t r g o n s i e h l t c t t o i r w h S T . . 2 1

m y e l t e r t s l o e y l l a p s g e n m m i n s o i s l s o c  i o i n o m g n t e i g t s d m n u n e i t l u t o o t n n r i o e c r u e e v v h o s g - m e g i m e p o s e a h t r s e s r s o p o p o t r y o i o m P l I C S S o t . . . . . 1 2 3 4 5

h g i ) h . l y o t c o , s r e o r g t c o n o  i m d ( n n e e a p v s m i r e a D s s d a o M N . . 1 2


e n i l n r u t e R

t s a  o g o o t t i n o g n d n e e i g t t p o n e ( a s e h e p c m y t n i o t e i t g l c n b e i a t h i s c s t u t i s s ) w n o r s a S U c  . . 2 1

e s o o l s e n i L . 1

s r a e g d : d e r s a u r l o t B s a . s e l r u w P o l : m s o e y r u v l o i r e c t t c h a e c e t e p r  o O h t u e r i s d w s ) p m s e r e i t m p n e a e g t n r s s i b h y g m c s r e i t r a o h m w F c ( s

h g i h o o t p m u p f o y c n e u q e r f g n i p p o t s d n a g n i t r a t S . 9


p o r p m i t e s e v l a v g n i p p o t y s t r l o u a g  n r i t r o y a t l r S e . 1

l l a m s o o t p m u p p m : s u r P e o t v i a t l c u e  m e d u c p c a m r u o P F . . 2 1

85

Annex 1 B

Notices on maintenance

(on the basis o the “General operating instructions 0/1” according to BOSCH, version 1.0, pages 63ff.) The saety notices listed in the ollowing have to be observed at all times and careully. • Conduct all maintenance works in due time, properly, and completely. • All employees have to be inormed beore starting any maintenance works. • The maintenance area has to be secured in a wide-ranging manner beore starting any works. • Corresponding signs have to inorm about maintenance works. • Signposts have to be attached to the control cabinet, the circuit breaker, actuators, and access in particular. • I the hydraulic assembly has to be switched off, it has to be secured against unintended re-closing by the ollowing measures: • All drives have to be switched off and the hydraulic system has to be disconnected rom the mains using the circuit breaker. • The pressure o the hydraulic assembly or component has to be reduced. • Possibly existing accumulators have to be depressurized. • The circuit breaker has to be secured against unscheduled re-closing. Prior to every manual intervention on the hydraulic component: All required details on depressurization and on the hydraulic components that are not depressurized automatically can be ound in the corresponding operating instructions. • Cylinders have to be moved to the sae stop position. • All loads have to be lowered. • All pumps have to be turned off. • All vertical cylinders have to be supported mechanically against lowering. Maintenance works on lifed units must not be conducted without securing the units externally. • Existing accumulators have to be depressurized properly. • The pressure supply has to be switched off and the hydraulic assembly has to be secured against unscheduled re-closing. • It has to be ensured that only authorized personnel stays in the work area. • The required personal protection equipment has to be used. • The sections o the system and pressure lines to be opened have to cool down beore starting any maintenance works. • Pressurized segments have to be opened slowly.

86

• Due to check valves in the pressure lines above the pumps, the hydraulic system may still

•

•

•

• • • •

be under pressure afer disconnecting it rom the proper pressure supply. Some segments, e. g. servo cylinders, still remain pressurized due to the locked position o the proportional valves (the hydraulic scheme contains all valves in basic position). Only new and tested components and spare parts identical in construction and lubricants in OEM quality are admissible or replacement/use. Installing used and untested components is strictly orbidden due to saety reasons. During maintenance works which possibly require the removal o certain saeguarding equipment, machine movements must only be carried out with the utmost care. The saeguarding equipment has to be re-installed and tested or unctionality beore every commissioning procedure. Welding, burning, or grinding works on the hydraulic aggregate or its superstructures must only be conducted upon approval o the local saety official and using appropriate protective covers against contaminations. When conducting installation works above body height o the operator, dedicated climbing aids and work platorms have to be used. System parts must not be used as climbing aid. Tools and devices required or the maintenance works have to be removed rom the machine/system. Leakages have to be remedied immediately at all times. The personnel have to be inormed about restarting the machine/system beorehand at all times.

87

Annex 1 C

Scope o visual inspection

(beore initial and re-commissioning) The ollowing scope o testing is recommended: • Does the hydraulic control system, including all connections o the individual parts,

correspond to the hydraulic scheme and the system description? • Do the data given on the nameplate and in the operating instructions correspond to

the data o the energies provided? • Are there main control units or all energies supplied? • Are there devices or reducing the energy (depressurization units)? • Have all measurement, venting, and bleeding points, as well as all parts been marked

in accordance with the hydraulic circuit diagram? • Have the hydraulic valves used as “device or rescuing persons” been marked in

accordance with the operating instructions? • Are monitoring devices or all saety-relevant system parameters (e. g. pressure, low,

temperature, oil level) installed and visible? • Have all actuators been marked practicably and can they be operated quickly, saely,

and clearly (especially or manually controlled systems)? • Have the setting values on all adjustable hydraulic parts (e. g. pressure relie valves,

throttle valves, pressure switches) been marked in accordance with the hydraulic circuit diagram? • Do all warning signs (especially or hydraulic accumulators and energy saved other-

wise) exist? • Have all pipelines been selected and installed in accordance with the hydraulic circuit

diagram and parts list and installed according to section 4.2? • Have all hose assemblies been selected, marked and installed in accordance with the

hydraulic circuit diagram and parts list and installed according to section 4.3.4? • Have hose assemblies not been used in line areas with higher requirements (e. g.

keeping a load elevated)? • Are hose assemblies, i required, equipped with an efficient protection against lash-

ing and/or leakages o hydraulic luids? • Have all saety devices been installed and do they comply with the system

description? • Are planned emergency stop devices available? • Have the hydraulic accumulators used been subjected to an equipment and installa-

tion test (and urther pressure equipment i required).

88

complied with?

Annex 1 D

Scope o testing o unctional test

The ollowing scope o testing is recommended:

complied with?

• Have the setting values o all settable hydraulic parts been set in accordance with the

labeling and have the settings been saved? • Does the hydraulic control system comply with the intended unction and does this

unction correspond to the system description? • Do all saety circuits work in accordance with the system description? • Do all emergency stop devices work and do they work in accordance with the system

description? • Is re-closing only possible afer saety conditions are ulfilled? • Does the operation o the emergency stop devices not result in additional hazards and

does their deactivation not result in automatic start? • Are there no hazards due to interaction with linked systems (locks)? • Do the control devices or starting and shutting down work in accordance with the

system description? • Are all monitoring devices o the saety-relevant system parameters unctional? • Are the devices or reducing still existing energy efficient and can they be used without

any risks afer disconnection rom the energy supply? • Do switching the energy supply on and off, energy reductions, as well as ailure and

return o the energy not lead to hazards? • Does using the system as intended not result in extraordinarily high pressure surges

or pressure boosts? • For testing any part o the hydraulic system with the maximum operating pressure that

can be achieved under all intended applications: – Have no measurable leakages occurred? – Did all hydraulic parts withstand the pressure? • Does the system temperature not exceed the thresholds specified in the system

description? • Does all user inormation relevant or operating the hydraulic system in a sae manner

exist (e. g. hydraulic circuit diagram, parts list, system description, drawings, operating/maintenance instructions, documents on hydraulic accumulators, saety data sheets on the hydraulic luids used, etc.)?

89

Annex 1 E

Scope o testing o sae provision and use

The ollowing scope o testing is recommended: • Do the operating and ambient conditions o the machine still comply with the intend-

ed use? For this, the ollowing has to be observed or example: – product type, cycle times, number o units – pressures, lows, and temperatures in the hydraulic system – hydraulic luid(s) used – velocities/stopping times o the dangerous movements – moved/elevated masses – type o eeding and removal – installation location – external inluences (e. g. vibrations, moisture, contaminations, mechanical inluences, ambient temperature, etc.) – position o the transport paths and type o means o transportation – space and access or operation and maintenance – arrangement and attachment o accessories – interaction with other machines • Is the user inormation o the manuacturer still complete and existing? • Are all saeguarding devices mentioned in the user inormation still existing and

installed? • Do all saety devices work in accordance with the system description, e. g.

saety distances (especially afer changing the application conditions), – secondary protective measures (especially afer changing the application and ambient conditions)? –

• Are the provided emergency stop devices existing and efficient and does the effect

correspond to the system description? • Is restarting only possible afer restoring the sae condition? • Does the operation o the emergency stop devices not result in additional hazards and

does their deactivation not result in automatic start? • Are there no hazards due to interaction with linked systems (locks)? • Do the control devices or starting and shutting down work in accordance with the

system description? • Have the setting values o all settable hydraulic parts (e. g. pressure relie valves,

throttle valves, pressure switches) been set in accordance with the specifications and have the settings been saved?

90

complied with?

(Continued) The ollowing scope o testing is recommended:

complied with?

• Are all monitoring devices o the saety-relevant system parameters unctional (e. g.

pressure, low, temperature, oil level)? • Are all signposts and warning signs, as well as labels on parts, lines, measurement

points, connection openings, depressurization devices, or the like still existing and can these be read? • Do all depressurization and shut-off devices, including their devices against unau-

thorized re-closing, work as intended? • Do the hose assemblies used show none o the deficiencies mentioned in section

4.3.5? In case o detected deficiencies section 4.3.6 has to be ollowed • Are the protective measures against lashing and/or leakages o hydraulic luids on the

relevant hose assemblies still existing or are they installed? • Have the periods or recurring tests on the pressure devices used (hydraulic accumu-

lators) been adhered to? I required, these have to be conducted or arranged by the operator. • Have the maintenance intervals been adhered to and has the lietime o wearing parts

been considered as recommended by the manuacturer? • Have the recommended replacement intervals or the hydraulic luid, as well as the

measures or maintaining the purity class been observed? • In case o modifications to the machine and in the hydraulic system (control system

and equipment), as well as afer more complex maintenance works, especially i pipes had to be re-routed, the test extent has to be expanded reasonably as or new systems in accordance with section 7.2, e. g.: – design and unction o the hydraulic control system – pressure surge, pressure boosts – pressure test – maximum system temperature and noise level – energy supply (switching on and off, reduction, ailure and return) – selection and installation o additional and newly installed pipelines and hose assemblies • Have all changes been identified and have these been incorporated into the docu-

mentation o the machine?

91

Annex 1 F

Involvement o staff members

From the German accident prevention regulation „Basic principles o prevention” (BGV A1)

General support obligations and behavior §15 (1) In accordance with their possibilities, as well as according to the instructions and orders o the entrepreneur the insured are obliged to provide or their saety and health at work, as well as or the saety and health o those affected by their actions or omissions. The insured have to support the measures or preventing occupational accidents, occupational diseases, and work-related health risks, as well as or an efficient first aid. Insured have to ollow the corresponding instructions o the entrepreneur. The insured must not ollow orders that are obviously directed against saety and health. (2) Insured must not induce a condition by consuming alcohol, drugs, or other intoxicating agents due to which they could endanger themselves and others. (3) Section (2) is also applicable to taking medicaments.

Special support obligations §16 (1) The insured have to report any identified direct substantial hazards or saety and health, as well as any deects regarding the saeguarding measures and protection systems immediately to the entrepreneur or the responsible supervisor. Without prejudice to this obligation the insured should also report identified hazards or saety and health and deficiencies regarding saeguarding measures and protection system to the specialist or occupational saety, the company doctor, or the saety official. (2) I an insured notices that regarding the prevention o occupational accidents, occupational diseases, or work-related health hazards • work equipment or other devices show deficiencies, • substances are not packaged, marked, or composed properly or • a work procedure is deficient,

he has to remedy the deficiencies immediately as ar as this is part o his job and i he is authorized to do so. Otherwise, he has to report the deficiency to the superior immediately.

92

Using acilities, work equipment and substances §17 Insured have to use acilities, work equipment, and substances, as well as saeguarding measures as intended and within the ramework o the jobs assigned to them.

Access and remaining prohibitions §18 Insured must only remain at dangerous spots within the ramework o the jobs assigned to them.

93

Annex 2 Provisions, Rules and Reerences

In the ollowing, the provisions and rules are compiled that have to be observed par ticularly or maintenance work on hydraulic systems.

1.

Laws, provisions and technical rules * Reference: Book trade and Internet: e. g. www.gesetze-im-internet.de • German Occupational Saety Law (ArbSchG), • German Ordinance on Occupational Saety and Health (BetrSichV), • German Hazardous Substances Ordinance (GeStoffV), • German Noise and Vibration Work Saety Regulation (Lärm-Vibrations-ArbSchV), • German Product Saety Act (ProdSG), • TRBS 1112 Technical rule or operating saety „Maintenance“, • TRBS 1201 Technical rule or operating saety „Tests o work equipment and

systems requiring monitoring“, • TRBS 1203 Technical rule or operating saety „Authorized persons“, • TRGS 150 „Skin resorbing hazardous substances“, • TRGS 555 „Operating instructions and Instructions according to § 20 GeStoffV“.

2.

BG provisions, rules, and inormation or saety and health at work * Reference: Your relevant accident insurer or at www.dguv.de/publikationen

Accident prevention regulations • DGUV Vorschrif 1 „Basic principles o prevention“, • DGUV Vorschrif 3 and 4 „Electric systems and utilities“ (ormer BGV/GUV-V A3), • DGUV Vorschrif 52 and 53 „Cranes“ (ormer BGV/GUV-V D6), • DGUV Vorschrif 54 and 55 „Winches, lifing and pulling units“ (ormer BGV/GUV-V D8), • DGUV Vorschrif 68 and 69 „Industrial trucks“ (ormer BGV/GUV-V D27), • DGUV Vorschrif 70 and 71 „Vehicles“ (ormer BGV/GUV-V D29). 94

Rules • DGUV Regel 113-004 „Containers, silos, and confined spaces“ (ormer BGR/GUV-R 117), • DGUV Regel 101-003 „Handling moving road construction machines“ (ormer BGR 118), • DGUV Regel 113-007 „Handling hydraulic luids“ (ormer BGR 137), • DGUV Regel 114-007 „Aircraf maintenance“ (ormer BGR 142), • DGUV Regel 109-008 and 109-009 „Vehicle maintenance“ (ormer BGR/GUV-R 157), • DGUV Regel 101-005 „Hoistable person-accommodating devices“ (ormer BGR/GUV-R 159), • DGUV Regel 112-189 and 112-989 „Use o protective clothing“ (ormer BGR/GUV-R 189), • DGUV Regel 112-198 „Use o personal protection equipment against alling down“ (ormer BGR/GUV-R 198), • DGUV Regel 113-015 „Hydraulic hose assemblies“ (ormer BGR 237), • DGUV Regel 100-500 and 501 „Operating work equipment“ (ormer BGR/GUV-R 500). Inormation • DGUV Inormation 213-001 „Working in confined spaces“ (ormer BGI 534), • DGUV Inormation 209-015 „Maintenance technicians“ (ormer BGI 577), • DGUV Inormation 201-029 „Handling instructions or selecting and operating work platorms on hydraulic excavators and loaders“ (ormer BGI 872), • DGUV Inormation 212-017 „General preventive guidelines or skin protection“ (ormer BGI/GUV-I 8620).

3.

Standards Reference: Beuth-Verlag GmbH, Burggrafenstraße 6, 10787 Berlin, Germany • DIN EN ISO 4413 Hydraulic luid power - General rules and saety requirements or systems and their components.

95

4.

Other specifications* Reference: Fachbereich Holz und Metall, Postfach 3780, 55027 Mainz, Germany • Fachausschuss-Inormationsblatt 015 „Prüen und Auswechseln von HydraulikSchlauchleitungen“, version 04/2010 Reference: Bosch Rexroth AG, Postfach 300240, 70442 Stuttgart, Germany • General operating instructions 0/1 by Bosch, edition 1.0.

5.

Reerences* Reference: Fachbereich Holz und Metall, Postfach 3780, 55027 Mainz, Germany • Fachausschuss-Inormationsblatt 046 „Hydropneumatische Druckspeicher“, version 11/2014.

* Only available in German. Photographs and graphics in this inormation by courtesy o the members o the committee o experts „Hydraulics and pneumatics“ o the accident insurers, expert committee woodworking and metalworking (FBHM), specialist area o effects upon health and media (SG MAF), specialist field o hydraulics and pneumatics, Isaac-Fulda-Allee 18, 55124 Mainz, Germany.

For queries: Questions with regard to BGI/GUV-I 5100 and BGI/GUV-I 5100 E can be addressed to the specialist: Reinried Stollewerk, Tel. ++ 49 (0) 221 56787-15077, [email protected]. 96

DGUV Information 209-071 English

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