Rubber hoses and hose assemblies - Wire braid reinforced compact type for hydraulic applications - Specification; German version EN 857:2015
1Key Takeaways
This European Standard specifies the requirements for two classes of wire braid reinforced compact hoses and hose assemblies with nominal inside diameters from 6 to 25, types 1SC and 2SC. They are suitable for use with: ——hydraulic fluids conforming to ISO 6743-4, except HFD R, HFD S and HFD T, in the temperature rang…
2Expert Interpretation
An in-depth look at the DIN EN 857:2016-09 standard for wire braid-reinforced compact hydraulic hoses, covering the technical requirements, dimensional specifications, performance testing, and certification process for both 1SC and 2SC types. Suitable for ISO 6743-4 hydraulic oil, water-based fluid, and water-based media applications.
Standard Overview and Technical Background
DIN EN 857:2016-09 is the technical specification for wire-braid-reinforced compact hydraulic hoses published by the German Institute for Standardization. This standard replaces the 1997 version and reflects the latest developments in hydraulic hose technology. This standard applies to 1SC single-layer steel wire braided hose and 2SC double-layer steel wire braided hose with a nominal inner diameter of 6 to 25 mm. The operating temperature range covers -40°C to +100°C (for hydraulic oils) and -40°C to +70°C (for water-based fluids).
Main technical updates
Compared with the 1997 version, the 2016 version of the standard has undergone major technical revisions: updated inner diameter tolerances, adjusted wear resistance test methods (due to the withdrawal of ISO 6945), and newly added normative Appendix A (wear resistance measurement), Appendix B (type test) and informative Appendix C (production acceptance test).
| Technical Parameters | 1SC Single Braid | 2SC Double Braid | Test Standards |
|---|---|---|---|
| Maximum Working Pressure (bar) | 88-225 | 165-400 | EN ISO 1402 |
| Burst Pressure (bar) | 352-900 | 660-1600 | EN ISO 1402 |
| Number of Pulse Cycles | 150,000 cycles | 200,000 cycles | EN ISO 6803 |
| Minimum bend radius (mm) | 75-230 | 75-250 | As specified in Table 5 |
Material Structure and Dimensional Requirements
The hose construction consists of an oil- and water-resistant synthetic rubber liner, one or two high-strength steel wire braids, and an oil- and weather-resistant synthetic rubber outer layer. Dimensional tolerances are strictly enforced, with an inside diameter tolerance of ±0.5mm and concentricity deviation within 0.4-1.3mm depending on the nominal diameter.
Detailed Explanation of Performance Test Requirements
Hydraulic Performance Test
Hydraulic pressure testing is conducted in accordance with EN ISO 1402, requiring a length change of no more than +2% to -4% under operating pressure. Pulse testing is conducted at 100°C, with Type 1SC required to withstand 150,000 cycles at 125% of the operating pressure, and Type 2SC required to withstand 200,000 cycles at 133% of the operating pressure.
Environmental Adaptability Test
Low-temperature flexibility testing is conducted at -40°C, requiring the lining and outer layer to be crack-free. Fluid resistance testing includes oil resistance (ISO 1817), water-based fluid resistance, and water resistance testing, with strict limits on volume expansion.
New abrasion resistance test method
Appendix A specifies a new abrasion resistance test procedure, using a special abrasive tool (hardness HV 890) to perform 2000 cycles under a vertical force of 25N, with a mass loss of no more than 0.5g.
Marking and certification requirements
Hoses must be marked with the manufacturer's logo, standard number, type, nominal diameter, and quarter and year of production every 500mm. Hose assemblies must also be marked with the assembler's logo, maximum working pressure, and assembly date.
Implementation recommendations and application guidelines
When selecting hydraulic hoses, the appropriate type should be selected based on the actual working pressure, media type, and ambient temperature. Type 1SC is suitable for medium pressure applications, and Type 2SC is suitable for high pressure conditions. In particular, castor oil-based and ester-based fluids must not be used, and special standards must be followed for underground mining applications.
It is recommended that users establish a regular inspection system and conduct type tests and production acceptance tests in accordance with the requirements of Appendices B and C to ensure that the hose assemblies always meet the safety standards.