Bsi bs en 01804 2 2001 + a1 2010

BRITISH STANDARD

Machines for
underground mines —
Safety requirements for
hydraulic powered roof
supports —
Part 2: Power set legs and rams

ICS 73.100.10

NO COPYING WITHOUT BSI PERMISSION EXCEPT AS PERMITTED BY COPYRIGHT LAW

BS EN
1804-2:2001
+A1:2010


BS EN 1804-2:2001+A1:2010

National foreword
This British Standard is the UK implementation of
EN 1804-2:2001+A1:2010. It supersedes BS EN 1804-2:2001 which is
withdrawn.
The start and finish of text introduced or altered by amendment is
indicated in the text by tags. Tags indicating changes to CEN text
carry the number of the CEN amendment. For example, text altered by
CEN amendment A1 is indicated by !".
The UK participation in its preparation was entrusted to Technical
Committee MRE/1, Mining mechanical equipment and machinery.
A list of organizations represented on this committee can be obtained

on request to its secretary.
This publication does not purport to include all the necessary
provisions of a contract. Users are responsible for its correct
application.
Compliance with a British Standard cannot confer immunity
from legal obligations.

This British Standard, having
been prepared under the
direction of the Engineering
Sector Policy and Strategy
Committee, was published
under the authority of the
Standards Policy and Strategy
Committee on 31 May 2002

© BSI 2010

ISBN 978 0 580 68143 1

Amendments/corrigenda issued since publication
Date

Comments

30 April 2010

Implementation of CEN amendment A1:2010

EUROPEAN STANDARD

EN 1804-2:2001+A1

NORME EUROPÉENNE
EUROPÄISCHE NORM

January 2010

ICS 73.100.10

Supersedes EN 1804-2:2001

English Version

Machines for underground mines - Safety requirements for
hydraulic powered roof supports - Part 2: Power set legs and
rams
Machines pour mines souterraines - Exigences de sécurité
relatives aux soutènements marchants applicables aux
piles - Partie 2: Etanỗons et vộrins pose mộcanisộe

Maschinen fỹr den Bergbau unter Tage Sicherheitsanforderungen für hydraulischen Schreitausbau
- Teil 2: Stempel und Zylinder

This European Standard was approved by CEN on 21 September 2001 and includes Amendment 1 approved by CEN on 21 December
2009.
CEN members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this European
Standard the status of a national standard without any alteration. Up-to-date lists and bibliographical references concerning such national
standards may be obtained on application to the CEN Management Centre or to any CEN member.

This European Standard exists in three official versions (English, French, German). A version in any other language made by translation
under the responsibility of a CEN member into its own language and notified to the CEN Management Centre has the same status as the
official versions.
CEN members are the national standards bodies of Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia,
Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland,
Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland and United Kingdom.

EUROPEAN COMMITTEE FOR STANDARDIZATION
COMITÉ EUROPÉEN DE NORMALISATION
EUROPÄISCHES KOMITEE FÜR NORMUNG

Management Centre: Avenue Marnix 17, B-1000 Brussels

© 2010 CEN

All rights of exploitation in any form and by any means reserved
worldwide for CEN national Members.

Ref. No. EN 1804-2:2001+A1:2010: E


BS EN 1804-2:2001+A1:2010
EN 1804-2:2001+A1:2010 (E)

Contents

Page

Foreword ..............................................................................................................................................................3 
Introduction .........................................................................................................................................................4

1

Scope ......................................................................................................................................................4 

2

Normative references ............................................................................................................................5 

3

Terms and definitions ...........................................................................................................................5

4

List of hazards........................................................................................................................................7 

5

Safety requirements ..............................................................................................................................7 

6

Verification of the safety requirements ............................................................................................ 11

7

User information ................................................................................................................................. 12 

Annex A (normative) Tests for verification of the safety requirements ..................................................... 17
Annex B (normative) List of tests ................................................................................................................... 30 

Annex ZA (informative) !Relationship between this European Standard and the Essential
Requirements of EU Directive 2006/42/EC"
" .................................................................................. 36
Bibliography ..................................................................................................................................................... 37 

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EN 1804-2:2001+A1:2010 (E)

Foreword
This document (EN 1804-2:2001+A1:2010) has been prepared by Technical Committee CEN/TC 196
"Machines for underground mines - Safety", the secretariat of which is held by DIN.
This European Standard shall be given the status of a national standard, either by publication of an identical
text or by endorsement, at the latest by July 2010, and conflicting national standards shall be withdrawn at the
latest by July 2010.
Attention is drawn to the possibility that some of the elements of this document may be the subject of patent
rights. CEN [and/or CENELEC] shall not be held responsible for identifying any or all such patent rights.
This document includes Amendment 1, approved by CEN on 2009-12-21.
This document supersedes EN 1804-2:2001.
The start and finish of text introduced or altered by amendment is indicated in the text by tags ! ".
!This European Standard has been prepared under a mandate given to CEN by the European Commission
and the European Free Trade Association, and supports essential requirements of EU Directive(s).
For relationship with EU Directive(s), see informative Annex ZA, which is an integral part of this document."
This standard is Part 1 of a European Standard specifying the safety requirements for hydraulic powered roof
supports.
Other parts are:
Part 1: Support units and general requirements
Part 3: Hydraulic control systems

Part 41): Electro-hydraulic control systems
Annexes A and B are normative.
This standard includes a Bibliography.
According to the CEN/CENELEC Internal Regulations, the national standards organizations of the following
countries are bound to implement this European Standard: Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech
Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia,
Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain,
Sweden, Switzerland and United Kingdom.

1)

in preparation

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EN 1804-2:2001+A1:2010 (E)

Introduction
This European Standard is a Type C-standard as stated in EN 1070
The extent to which hazards are covered is indicated in the scope of the standard.
While producing (or when compiling) this standard it was assumed that:


only trained and competent persons operate the machine;



components without specific requirements are:

a)

designed in accordance with the usual engineering practice and calculation codes;

b)

of sound mechanical construction;

c)

free of defects.



components are kept in good working order;



negotiations have taken place between the user and the manufacturer of the legs and rams
(manufacturer of the roof support unit or final user in case of replacement parts) concerning the use of the
machinery.

1

Scope

This standard specifies the safety requirements for legs and rams when used as specified by the
manufacturer or his authorised representative. Examples covered by the standard include legs, support rams
and rams with their mechanical extensions, internal valves and safety devices, seals, hydraulic connections

(up to the first hose or Type B valve, see Part 3) and their lifting points but excluding protective pipes and
gaiters, external valves and hydraulic and electrohydraulic control systems.
NOTE

Some components are dealt with in other parts of this standard.

This standard applies to legs, support rams and rams used at ambient temperatures from –10 °C to 60 °C.
This standard identifies and takes account of:


Possible hazards which may be caused by the operation of legs, support rams and rams;



Areas and operating conditions which may create such hazards;



Hazardous situations which may cause injury or may be damaging to health.

This standard describes methods for the reduction of these hazards.
A list of hazards covered appears in clause 4.
This standard is applicable to all legs, support rams and rams placed on the market for the first time and which
are manufactured after the date on which this standard was published.
This European standard does not establish the additional requirements for:

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EN 1804-2:2001+A1:2010 (E)



Specially corrosive environments;



Hazards occurring during construction, transportation, decommissioning;



Earthquake.

2

Normative references

This European Standard incorporates by dated or undated reference, provisions from other publications.
These normative references are cited at the appropriate places in the text, and the publications are listed
hereafter. For dated references, subsequent amendments to or revisions of any of these publications apply to
this European Standard only when incorporated in it by amendment or revision. For undated references the
latest edition of the publication referred to applies (including amendments).
EN 287-1, Approval testing of welders - Fusion welding – Part 1: Steels
EN 288-1, Specification and approval of welding procedures for metallic materials – Part 1: General rules for
fusion welding
EN 288-2, Specification and approval of welding procedures for metallic materials – Part 2: Welding procedure
specification for arc welding
EN 288-3, Specification and approval of welding procedures for metallic materials – Part 3: Welding procedure
tests for the arc welding of steels

EN 292-2:1991 + A1:1995, Safety of machinery - Basic concepts, general principles for design – Part 2:
Technical principles and specifications
EN 1050:1996, Safety of machinery – Principles for risk assessment
EN 1804-1:2001, Machines for underground mines - Safety requirements for hydraulic powered roof supports
– Part 1: Support units and general requirements
!EN 1804-3", Machines for underground mines - Safety requirements for hydraulic powered roof supports
– Part 3: Hydraulic control systems
EN 10002-1, Metallic materials - Tensile testing – Part 1: Method of test
EN 10045-1, Metallic materials - Charpy impact test – Part 1: Test method
prEN 13463-1:1999, Non-electrical equipment for potentially explosive atmospheres – Part 1: Basic
methodology and requirements
ISO 7745:1989, Hydraulic fluid power - Fire-resistant (FR) fluids - Guidelines for use
EURONORM 103:1971, Microscopic determination of the ferrite or austenitic grain size of steels

3

Terms and definitions

For the purposes of this standard the following terms and definitions apply.
3.1
support unit
type of hydraulic powered roof support e.g. frame support, chock support, shield support, consisting of support
components and support accessories [EN 1804-1:2001]

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EN 1804-2:2001+A1:2010 (E)

3.2
support components
all components which lie within the flow of the support bearing force
3.2.1
actuator
any type of hydraulic linear reciprocating device referred to in this standard
3.2.2
legs and support rams
hydraulic actuators for producing the support bearing force of the support unit
3.2.3
single telescopic legs and support rams
hydraulic legs and support rams with one extension stage
3.2.4
multi telescopic legs and support rams
hydraulic legs and support rams with several extension stages
3.3
rams
all actuators which do not lie within the flow of the support bearing force but which are necessary for the
functioning of the powered roof support
3.4
valve
device for controlling the hydraulic functions
3.5
pressures
3.5.1
setting pressure
hydraulic pressure in the legs and support rams on completion of the setting procedure. This pressure is
supplied by the hydraulic system
3.5.2
yield pressure of an actuator

Hydraulic pressure in an actuator when the relevant pressure limiting valve is opened. This pressure in the
actuator is induced by external forces (yield forces; see 3.5.2 of EN 1804-1:2001).
3.5.3
maximum permissible working pressure of an actuator
maximum hydraulic pressure at which a hydraulic component is intended be operated and/or yielded
3.6
rated actuator force
Maximum force to which an actuator is designed. It is a calculated value which is determined from the actuator
geometry and the maximum permissible working pressure, neglecting friction.
3.7
functions
3.7.1
extension
pushing out of the actuator operating piston by means of hydraulic pressure

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EN 1804-2:2001+A1:2010 (E)

3.7.2
retraction
drawing in of the actuator operating piston by means of hydraulic pressure
3.7.3
setting
extending of the support unit between the roof and the floor by pressuring the legs and support rams
3.7.4
yielding
alteration in length of an actuator which occurs when external forces cause the yield pressure to be exceeded

4

List of hazards

All the items in the following list of hazards refer to continuous operation and to installation and maintenance.
This list contains the hazards and hazardous situations, as far as they are dealt with in this European
Standard, identified by risk assessment as being significant for this type of machinery and which require action
to eliminate or reduce risk.
Table 1 — List of hazards with cross references to safety requirements
No.

EN 1050:1996

Safety requirements (clause)

Hazards

1

1.1; 1.2; 1.3

5.8

Crushing, shearing and cutting

2

1.9

5.2; 5.4

High pressure fluid jets

3

17

5.2; 5.6; 5.7; 5.8

Ejected parts

4

1e; 1.8

5.2; 5.5; 5.6; 5.7; 5.8; 5.10 to 5.13

Fatigue, overload; friction or wear

5

2.4

5.12.3

Electrical
energy
resulting
electrostatic phenomena

6

7.1

5.9

Inhalation of harmful fluids, mists and
fumes

7

7.2

5.3; 5.12.2

Fire or explosion

8

17

5.4 to 5.14

Unexpected ejection of machine parts
or fluids

5.15

Errors of fitting

9

5
5.1

from

10

27.8

5.1; 5.15

Absence or incorrect installation of
devices and accessories for assembly
and maintenance

11

10.6

5.1; 5.15

operating error

12

1.C

5.1; 5.15.

Potential energy of actuators parts
which may move under the effect of
gravity

Safety requirements
Lifting points

Where lifting points are fitted to actuators they shall be suitable for their intended purpose. They shall be
designed to have a calculated minimum factor of safety of 4 on ultimate breaking load in relation to their

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EN 1804-2:2001+A1:2010 (E)

intended load carrying capacity. They shall be clearly and permanently marked with their load carrying
capacity e.g. by welding.

5.2

Internal valves and safety devices

Actuators, that can be externally overloaded, shall be protected against excessive pressure.
This can be by means of
internal valves
external valves (see !EN 1804-3")
safety devices such as bursting blanks.

The pressure in the piston compartment of hydraulic legs shall be capable of being monitored so that
leakages are recognised in good time and hazards from inadequate strata control as a result of a pressure
drop in the legs are avoided.
As a result of the type of fluid used and the small number of pressure cycles per day, actuators of hydraulic
powered roof supports need neither to be self-bleeding nor shall they have external air bleeds.
In addition, internal valves, excluding constant yield valves, are covered by !EN 1804-3" of the standard.

5.3

Hydraulic fluids

Actuators shall be designed such that they may be used with:
a)

fire-resistant fluids category HFA (ISO 7745:1989) specified by the support unit manufacturer in according
to 6.2.1 of ISO 7745:1989

or
b)

water without additives.

NOTE
Hydraulic systems of roof supports, designed for coal mines and other mines with potentially explosive
th
atmospheres, should be designed for use with non-toxic and fire-resistant fluids in accordance with SHCMOEI 7 Report
(see Bibliography).

5.4

Protection against ejecting fluids

Actuators that intentionally eject fluid in to the atmosphere shall be designed to prevent any hazard due to the
releasing fluid (e.g. by means of a guard).

5.5

Yield capability

Legs and support rams shall be designed such that at yield pressure they are capable of supporting the forces
and the movements of attached components, see annex A (see 5.3.1 of EN 1804-1:2001).

5.6

Behaviour under axial overload

Legs and support rams, including their mechanical extensions, shall be designed so that their function is not
affected it they are subjected statically to 1,5 times the rated compressive or tensile force and dynamically to a
mechanical impact load resulting in 1,5 times the maximum permissible working pressure. (See annex A).
Where dynamic load testing is not practicable legs and support rams shall be subjected statically to 2 times
the rated compressive or tensile force.

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EN 1804-2:2001+A1:2010 (E)

Rams, including their mechanical extension pieces, shall be designed so that their function is not affected it
subjected statically to 1,5 times the rated compressive or tensile force. (See annex A).

In the fully retracted condition legs and support rams shall be capable of withstanding 2 times the rated
compressive force.

5.7

Eccentric loading

Legs and support rams including their extension pieces shall be capable of withstanding eccentric and/or
lateral forces without their function being impaired. (See annex A).

5.8

Functional reliability

The functional reliability of legs and supporting rams including their extension pieces shall not be impaired
after 21000 load cycles. (See annex A).

5.9

Leak tightness

Pressure compartments of actuators shall be leak tight when isolated. (See annex A).

5.10 Extension limit
Extension limits of legs and support rams shall withstand a pressure of at least 80 % of the maximum
permissible working pressure without damage when the fully extended piston is loaded 100 times with this
pressure. If the design of the hydraulic circuitry of the support unit is such that it is possible operationally to
generate pressures higher than 80 % of the maximum permissible working pressure, legs and support rams
shall remain undamaged at these higher pressures and under the above mentioned conditions.
Rams shall withstand 1,5 times the maximum permissible working pressure when the piston is in fully

extended in contact with the internal stop.
Support rams that are subjected to tensile load in operation shall not be damaged when they are fully
extended in contact with the internal stop and loaded with 1,5 times the rated tensile force.

5.11 Force introduction points of actuators
The force introduction points of actuators and their extension pieces shall be capable of withstanding 1,5
times the rated actuator force without their function being affected.

5.12 Materials
5.12.1 Steel
5.12.1.1

General

The tensile strength of the steel grades used shall be at least 1,08 times the determined yield point or 0,2 %
proof stress if the calculated stresses are more than 90 % of the permissible stresses (see 5.13.1).
The elongation at fracture (A) of the steel grades used shall be not less than 10 %.
5.12.1.2

Steel for welded actuator components

The steel shall be of fine grain, (ferrite grain size 6 or finer as described in EURONORM 103: 1971) and shall
have an impact value of at least 27 J at a temperature of -20 °C.

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EN 1804-2:2001+A1:2010 (E)

5.12.1.3

Steel for non-welded actuator components

The steel used for the non-welded tubes of actuators shall have properties as described in 5.12.1.1 and
5.12.1.2.
The steel used for the other components shall have an impact value of at least 25 J at a temperature of 20 °C.
5.12.2 Light metal
Surfaces of actuators consisting of light metal or light metal alloys (including paints and coatings containing
light metal) intended by the manufacturer to be used in potentially gaseous mines shall meet the requirements
of clause 8 of prEN 13463-1:1999.
5.12.3 Other materials
For materials that are used for the manufacturer of actuator components, equivalent ductility characteristics to
those specified for steel in 5.12.1 shall be proven. Non-metallic materials shall meet the requirements of
clause 7 of prEN 13463-1:1999.
5.12.4 Seals
Actuator seals shall full fill the test requirements given in annex A.

5.13 Calculated permissible stresses
5.13.1 Permissible stresses under axial central rated force conditions
The axial stresses in the individual parts of the actuators shall not exceed 70 % of the guaranteed yield point,
0,2 % proof stress or compressive limit of the materials (also valid for annular stresses as a result of fluid
pressure).
The axial stresses in the bases of actuators shall not exceed 80 % of the guaranteed yield point, 0,2 % proof
stress or compressive limit of the materials.
The shear stresses shall not exceed 65 % of the guaranteed yield point, 0,2 % proof stress or compressive
limit of the materials.
5.13.2 Permissible stresses under double axial central rated force conditions
In the case of twice the central rated force in the fully retracted state of legs and support rams, the stresses
shall not exceed the guaranteed yield point or 0,2 % proof stress of the materials.

NOTE

This requirement only involves mechanical loading. There are no hydraulic pressures.

5.13.3 Permissible stresses under eccentric rated force conditions
In the case of the eccentric rated force as described in A.1.3.1 the axial stresses of the leg and support ram
components involved in bending shall not exceed the guaranteed yield point or 0,2 % proof stress or
compressive limit of the materials. The deflections determined by means of a test as specified in A.1.3.2 shall
be used as a basis for calculating the stresses.
In the case of an eccentric rated force and simultaneous lateral loading (e.g. to stabilize the support unit), the
axial stresses of the leg and support ram components involved in bending shall not exceed the guaranteed
yield point or 0,2 % proof stress or compressive limit of the materials.

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EN 1804-2:2001+A1:2010 (E)

5.13.4 Permissible weld stresses
The weld stresses shall not exceed the permissible stresses of the adjacent materials given in Table 2, if the
welds are not subjected to any non-destructive testing.
Table 2 — Permissible weld stresses (5.13.1 to 5.13.3)
Weld types

Axial stresses

Shear stresses

Combined stresses

Fillet welds

65 %

65 %

100 %

Butt welds

80 %

80 %

100 %

Where these stresses are exceeded due to result of non-destructive testing the manufacturer shall document
them specially.

5.14 Welding
All welding shall be carried out in accordance with EN 288-1, EN 288-2 and EN 288-3. The manufacturer shall
make use of competent welding shops and welders. This can be reached by either:
a)

operating a certified quality system according to EN ISO 9001; or

b)

a certificate issued by an accredited body confirming compliance with the quality requirements of

EN 729-3.

The welding shall be done by welders qualified in accordance with EN 287-1.

5.15 Correct assembly and installation
It shall be possible to assemble and install the actuator correctly in accordance with the assembly instructions
or other documents provided by the manufacturer.

6
6.1

Verification of the safety requirements
Type testing

One specimen of the actuator shall be type tested in accordance with annex A. The test requirements given in
annex A shall be met. The following documents shall be made available to the laboratory running the type
test:


User information;



Results of a static calculation in accordance with A.2;



Manufacturing drawings;



Drawing of welded parts;



Evidence of the competence of the welding workshop;



Data relating to the material characteristics;



Data relating to the seals used.

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EN 1804-2:2001+A1:2010 (E)

NOTE

The specimen which has been tested according to Annex A should not be placed on the market.

If no provision has been made in annex A for verification of the requirements in clause 5 by specified tests,
they shall be verified by means of visual inspection, function test or reference to documents.
Verification of the safety requirements is shown in Table 3.
Table 3 — Tests for verification of the safety requirements
Safety requirements

Verification

5.1

*see A.1.5

5.2

*visual Inspection/comparison with manufacturer's drawings

5.3

*Inspection of the oil-manufacturer's test documentation

5.4

*visual Inspection/ comparison with manufacturer's drawings

5.5

*see A.1.2.2

5.6

*see A.1.2.3

5.7

*see A.1.3

5.8

*see A.1.4

5.9

*see A.1.2.4

5.10

*see A.1.2.1 and A.1.4.3

5.11

*see A.1.2.3.1

5.12

**see A.3

5.13

*see A.2

5.14

**see A.3.2

5.15

*Inspection of manufacturer's test documentation

*type test; **series test

6.2

Series verification

See Table 3; Verification with **

7
7.1

User information
General requirements

The actuator manufacturer shall provide user information meeting the requirements of clause 5 of EN 292
2:1991 + A1:1995 and clause 7.
The user information shall be the primary source of information on a complete actuator and shall contain all
the information relating to its safe application and this shall be produced as an instruction handbook as
specified in 5.5 of EN 292 2:1991 + A1:1995.
Clause 7 User information of EN 1804-1:2001 also applies to !EN 1804-3" and !prEN 1804-4") and
is complemented, as appropriate, by corresponding clauses in those parts.
Care shall be taken to ensure that the user information is available to the user on receipt of the actuator.

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EN 1804-2:2001+A1:2010 (E)

7.2

Technical and application data

7.2.1

Introduction

The user information shall describe the intended use of the actuator.
The operating instruction shall include all design and performance data necessary, either for the user or for
the manufacturer of the hydraulic powered roof support, to make an assessment of suitability for use in
particular applications and environments, and for the identification of any energy supply requirements and
other ancillary facilities that may be needed. The information provided shall comply with 7.2.2 to 7.2.5.
7.2.2

General description

This description shall explain in clear, easily understandable language of the user and in logical sequence the
overall function of the actuator with all special features and characteristics. General arrangement drawings
shall be provided as appropriate.
7.2.3

Performance data

The principal dimensions, weights, and performance data of the complete actuator shall be given.
7.2.4

Hydraulic data

The data necessary to design the hydraulic system including yield and setting characteristics shall be given. In
addition, it shall include a list of the hydraulic fluids specified by the manufacturer of the actuator (see 5.3).
7.2.5

List of additional drawings and documents

A complete list of all drawings, illustrations and other documents including e.g. information about welding
qualification, which are part of the information for use but provided separately from the user information, but
which form part of the information required by this standard shall be provided. The list shall include,
appropriate cross-reference to the text, of the user information.

7.3

Handling, transport and storage

7.3.1

Introduction

This section of the user information shall include information and instructions for the safe handling, transport
and storage of the actuator.
7.3.2

Handling and transport

The details shall include:
a)

Weights and outline dimensions of all the supplied actuators.

b)

Precautions to be taken during handling and transportation. In addition, indications of possible damage to
the actuators during handling and transport.

c)

Information on the number and rated load of any ancillary lifting equipment (e.g. shackles, eye bolts) not
supplied but necessary in order to enable safe lifting/installation of the actuators.

7.3.3

Storage

The following information shall be given for the storage of the actuator on the surface and underground:

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EN 1804-2:2001+A1:2010 (E)

a)

methods of preservation; and

b)

instructions for preparing the actuator for use after storage.

7.4

Installation, commissioning and operation

7.4.1

Installation

The installation of the actuator into the support unit shall be described together with details of any special tools
that may be required.
Reference shall be made to the user information supplied for the support unit (e.g. compatibility).
7.4.2

Commissioning

Details shall include:
a)

checking the correct installation prior to connection to the pressure supply and information on the
necessary cleaning and flushing procedures;

b)

connection of hydraulic pressure supply;

c)

commissioning the actuator and testing individual functions.

7.4.3

Operation

This section of the user information shall include the information and instructions necessary for the safe
operation of the actuators.
Details shall be given for the correct use, with information on the operating range and prohibited applications.

7.5

Maintenance

7.5.1

Introduction

This section of the user information shall contain the necessary information and instructions to enable the
actuator to be maintained in, or restored to, safe working order. The information provided shall be according to
7.5.2 to 7.5.5.
7.5.2

Maintenance instructions

Instructions shall be provided, with illustrations where necessary, detailing the methods and procedures for
preventative and corrective maintenance. The instructions shall include reference to the following:
a)

dismantling and re-assembly;

b)

replacement and adjustment;

c)

a parts identification list;

d)

special tools and additional equipment;

e)

hazards which may arise and precautions to be taken.

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BS EN 1804-2:2001+A1:2010
EN 1804-2:2001+A1:2010 (E)

7.5.3

Fault diagnosis and correction

Information and instructions shall be included on fault diagnosis and correction.
7.5.4

Preventative maintenance schedules

Schedules shall be provided and include information on the nature and frequency of inspections, tests,
maintenance and discard criteria required to keep the actuator in safe working order.
7.5.5

Technical Description

This shall be in the form of a comprehensive functional description of the actuator and its main components
with appropriate illustrations designed to enable the text to be kept concise and easily understandable. The
description shall include details of the safety devices and measures for preventing hazards that may arise
from malfunction of the equipment.

7.6

Parts identification lists

A parts identification list shall be provided which shall include the part numbers and sufficiently full
descriptions for positive identification of all assemblies, sub-assemblies and components of the actuator.
The list shall also identify:
a)

those parts which the manufacturer envisages being changed in the working environment; and

b)

those parts which the manufacturer recommends should be held as spares.

Parts identification lists shall be illustrated by drawings, photographs etc. as appropriate, so that each
component listed may be readily identified and located.

7.7

Marking

Each actuator shall be permanently marked with at least the following:
!
a)

the business name and full address of the manufacturer and, where applicable, his authorised
representative;"

NOTE

b)

If space is restricted the registered company logo or trademark can be used.

year of manufacture;

!
c)

designation of the machinery;"

d)

serial number, if any;

e)

maximum permissible working pressures;

f)

rated forces (tensile and compressive)
For marking of lifting points see 5.1.

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BS EN 1804-2:2001+A1:2010
EN 1804-2:2001+A1:2010 (E)

7.8

Residual risks

The user information shall inform the user of the residual risks when using the actuator.

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BS EN 1804-2:2001+A1:2010
EN 1804-2:2001+A1:2010 (E)

Annex A
(normative)
Tests for verification of the safety requirements

The tests described below and acceptance criteria are listed in Annex B.

A.1 Load tests
A.1.1 General
The tests shall be carried out on actuators including the extensions, the internal valves and safety devices, the
seals and the hydraulic connections. During the load tests, no damage shall occur which impairs the load
carrying capacity. However, impairment of the load carrying capacity is permissible in the case of double
overload test. No cracks shall occur in the parent metal or in the welds.
All measured values and results from the tests shall be recorded.

A.1.2 Testing with a central axial load
A.1.2.1

Testing the extension limit

Actuators shall be extended once without encountering any external resistance against the internal stop at the
maximum permissible working pressure according to 5.10. The actuator shall be left in this position for at least
3 min. Support rams that are subjected to tensile loads in operation shall be extended once, by an external
force, against the internal stop at 1,5 times the rated tensile force and shall be left in this position for at least 3
min.
A.1.2.2

Yield test

The legs and support rams shall be loaded with an initial load of approximately 10 % of the rated leg or
support ram force. The connected pressure limitation valves shall be adjusted to the maximum permissible
working pressure of the legs or support rams. Then 2 yield tests shall be carried out for each condition,
beginning at the fully extended condition, with the following travels and yield rates:


100 mm travel at (10 ± 2) mm/min



20 mm travel at (2 ± 1) mm/min.

In the case of multi-stage legs and support rams, additional yield tests shall be carried out over the stage
transitions over a travel of 100 mm at a yield rate of (10 ± 2) mm/min.
In the case of support rams that are subjected to tensile loads during operation, the above tests shall also be
carried out as extension tests.
NOTE
Support rams that are extended and retracted at higher speeds as a result of the kinematics of the support
unit should be subjected to additional retraction and extension tests at the rated maximum speeds.

The internal pressures and loads measured shall be recorded over the yield travel and plotted against time.
The measured yield or extension force shall be within +10 %, -0 % of the rated leg or support ram force.

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BS EN 1804-2:2001+A1:2010
EN 1804-2:2001+A1:2010 (E)

A.1.2.3
A.1.2.3.1

Overload tests
Static overload

The test may be carried out using one of the following alternative methods:
a)

Actuators with possible mechanical extensions shall be fully extended at 80 % of their maximum
permissible working pressure. Next, the pressure compartments shall be isolated. The actuators shall
then be subjected to an external force of 2 or 1,5 times the rated force (see 5.6). This force shall be
maintained whilst the leakage test as described in A.1.2.4 is carried out.
The force applied shall be recorded and plotted against time.

b)

Actuators with possible mechanical extensions shall be extended against an abutment at (95 3) % of
their maximum length. Next the pressure compartments shall be loaded with 2 or 1,5 times the maximum
permissible working pressure (see 5.6). Then the pressure compartments shall be isolated whilst the
leakage test as described in A.1.2.4 is carried out.
The pressure shall be recorded and plotted against time.

In the tests described in a) and b) at 1,5 times the rated force or maximum permissible working pressure, the
dilation of the cylinders shall be measured. The permanent dilation of the cylinder diameter shall not exceed
0,02 %.
In the case of actuators that will be subjected to tensile loads during operation, tests shall be carried out as in
a) and b) but starting at the fully retracted position and with the annular compartments subjected to load.
In addition, a test shall be carried out with legs and support rams fully retracted. They shall be subjected to an
external load of 2 times the rated force. This force shall be maintained for at least 3 min.
A.1.2.3.2

Dynamic overload

The test shall be carried out with legs and support rams at 70 to 80 % of their extended length but with a
residual travel of at least 100 mm per stage in the case of legs and at least 30 mm per stage in the case of
support rams. The legs and support rams shall be set with 60 % of the maximum permissible working
pressure and the pressure compartments shall be isolated. Then the legs and support rams shall be subjected
twice in succession to a sudden impact by means of a free-falling mass of at least 10000 kg for legs and at

least 1000 kg for support rams. This axial loading shall be applied centrally. A pressure of 1,5 times (± 5 %)
the value of the maximum permissible working pressure shall be attained. The pressure increase from its
initial value to the required pressure shall be measured with an adequate measuring device (e.g. oscillograph)
and be attained within a period of 30 ms. The internal pressure shall be recorded and plotted against time. For
multi-stage legs and support rams the recorded pressure shall be the pressure in the largest stage.
The functioning of the legs or support rams shall then be checked as described in A.1.2.2.
A.1.2.4

Leakage test

The following requirements apply to all leakage tests within the standard. Supplementary test parameters are
given in specific clauses.
During the leakage test the pressure compartments of the actuators to which the load is applied shall be
isolated. The pressure or the travel of the actuator shall be recorded and plotted against time. During the first
minute of test, the pressure shall not drop by more than 10 % or the actuator shall not change its length by
more than 1 %. For a further 5 minute period, the pressure or actuator length shall remain constant. For a
further 5 minute period, the pressure shall not change by more than 0,5 % and the actuator length shall not
change by more than 0,05 %.

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