BI645092-01

24. Aug. 2015

Service Magazine

New Options for Preventative/ Proactive Maintenance for

Hydraulic Hose Assemblies on Hydraulic Mining Shovels
6015 DHB15001 - up
6015 FS DHF15001 - up
6018 DHT18001 - up
6018 FS DHD18001 - up
6030 DHL30001 - up
6030 FS DHG30001 - up
6040 DHJ40001 - up
6040 FS DHX40001 - up
6050 DHM50001 - up
6050 FS DH250001 - up
6060 DHN60001 - up
6060 FS DH360001 - up
DHS90001- up
6090 FS
DM690015 - up

Attention: Follow appropriate safety procedures and use personal

protective equipment as required.

Corresponding local safety regulation must always be observed.

The purpose of this Service Magazine is to provide operational information for hydraulic hoses
and recommended change out intervals for hydraulic hoses on HMS machines.
The first section provides information how to handle and store hydraulic hoses. In the second
section recommendations on how to minimize unplanned downtimes and achieve the lowest
cost of ownership are made.

Caterpillar: Confidential Green

©2015 Caterpillar Cat, Caterpillar, their respective logos, “Caterpillar Yellow” and the Power edge trade dress, as well as corporate
Caterpillar Global Mining HMS GmbH, Karl Funke Str. 36, D-44149 Dortmund, Germany DF
2015-069-SM-BI645092-01 Guidelines for Servicing Hydraulic Hoses.docx Page 1 of 4
 BI645092-01

1. Operational information
1.1 General
 Hydraulic lines and hoses must never be repaired.
 Using hose assemblies close to the limit ranges of permitted use shortens the service
life (e.g. environmental influences as cold weather or high temperatures, frequent
working cycles, extremely high impulse frequencies).
 Service life should always be referred to operating hours (e.g. multi shift operation or
24hours operation collects more hours/ year).
 HMS usage in excess of manufactures recommended practices should be avoided to
achieve maximum life of hydraulic hoses.
 Recommended change-out of hose, particularly for hoses in critical areas, is related to
working hours / load and is provided later in this Magazine.

1.2 Storage
 Even if hydraulic hose assemblies are stored and used properly, they undergo a natural
aging process. For that reason their service life is limited.
 According to ISO 8331 bulk hose in general has a shelf life of up to 7 years from the
date of manufacture with an extension of 3 years, as long as the hose is stored in
accordance with ISO 2230.
 The overall service life of a hose assembly must not exceed 6 years, including a storage
period of not more than 2 years. Therefore built date/ hose assembly date shall be
traceable, e.g. imprint on ferrule, hose tag.
 Hose assemblies must always be stored straight either flat on shelving or hanging from
racking. Assemblies left coiled can affect the natural lay of the hose assembly therefore
affect angle settings for angled fittings. All hose assemblies must remain capped to
prevent contamination.

1.3 Inspection/ Preventative Maintenance

 Caterpillar continues to recommend Preventative Maintenance, with hoses being
inspected for signs of leaks, abrasion wear, cracked rubber, twisting, contact/ rubbing
and loss of flexibility on a regular frequency. Hoses exhibiting these characteristics
should be removed and replaced as soon as possible to prevent unplanned downtime
and loss of productivity.
 It is recommended that all hose assemblies are checked daily but at very least weekly
for external visible damage. Any damaged assembly should be replaced immediately.

1.4 Indications for Replacement

 Hose assemblies must be replaced if any of the following points are found during an
inspection:
- Damage on the external layer into the internal layer (chaffing, cuts, rips).
- Brittleness on the outer layer (crack formation of the hose material).
- Changes in shape, which differ from the natural shape of the hose, when under
pressure or not, or in bends or curves, such as separation of layers, blister or bubble
formation.
Caterpillar: Confidential Green
Caterpillar Global Mining HMS GmbH, Karl Funke Str. 36, D-44149 Dortmund, Germany
2015-069-SM-BI645092-01 Guidelines for Servicing Hydraulic Hoses.docx Page 2 of 4
 BI645092-01

- Leaks
- Non observance of installation requirements/ incorrect installation.
- Damage or deformation of hose fittings, which might reduce the strength of the fitting or
connection.
- Corrosion on fittings, which might reduce the function or strength of the fitting.
 Special Instruction BI644931 provides assembly and installation details for Code 61 and
Code 62 hydraulic hoses and further replacement recommendation for CAT dealer built
hose assemblies.

2. Recommended change intervals

 The advantages to setting up such change-out intervals is to minimize unplanned

downtimes and achieve the lowest cost of ownership. The given intervals reflect the best
mix between achievable life and maximum component utilization.
 Where possible the change-out intervals should be aligned with the recommended
service intervals for major components. Hydraulic Hose recommendations have been
developed to be integrated, if possible, with existing service intervals to reduce
unplanned machine downtime due to failure.
 These change out recommendations should be adjusted for site specific reasons and
performance history.
 Service intervals for hydraulic hoses listed below can now be utilized:
Clam Cylinder Hoses: 5,000 hours
Boom Cylinder Hoses: 10,000 hours
Stick Cylinder Hoses: 8,000 hours
Bucket Cylinder Hoses: 8,000 hours
Travel and Slew Hoses: 10,000 hours
Pilot Hoses: 20,000 hours
Oil Cooler & Return Hoses: 15,000 hours
Main Pump Hoses: 10,000 hours
Other high pressure hoses 10,000 hours
on superstructure

Caterpillar: Confidential Green

Caterpillar Global Mining HMS GmbH, Karl Funke Str. 36, D-44149 Dortmund, Germany
2015-069-SM-BI645092-01 Guidelines for Servicing Hydraulic Hoses.docx Page 3 of 4
 BI645092-01

Illustration 1: Recommended Service Intervals for Hydraulic Hoses

on Hydraulic Mining Shovels

Caterpillar: Confidential Green

Caterpillar Global Mining HMS GmbH, Karl Funke Str. 36, D-44149 Dortmund, Germany
2015-069-SM-BI645092-01 Guidelines for Servicing Hydraulic Hoses.docx Page 4 of 4