Pipework installation

procedure
Hägglunds products

Replaces:
Instruction -
RE DD000*****/02.2015 English
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1 Purpose

1.1 General
To ensure that all drives of Hägglunds pipe installations conform the specified
requirements.

2 Scope

2.1 General

This procedure applies to all pipe work installed for and by Bosch Rexroth Mellansel
AB

3 Responsibility

3.1 Sales engineer

It is the responsibility of the sales engineer to ensure this instruction is carried out
as per the procedure.

3.2 Service technician

It is the responsibility of the service technician to perform and inspect the pipe work
installation as per the procedure.

4 Procedure

4.1 Material
Generally, all equipment should be selected from high quality materials, designed to
operate under the conditions and pressures required by the drive system.

Recommended standards:

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a. Hoses SAE-R100 or AS 3791.

b. Tubes ASTM A179 Cold draw seamless hydraulic tube. (AS4041)
ASTM 2.69 Stainless steel seamless hydraulic tube.
c. Pipe (preferred) Material, St52.4 NBK according to DIN2391c.
Phosphated, high quality, bendable, cold drawn, seamless
carbon steel pipe.
Material SAF2304 or equivalent
High quality, bendable, cold drawn, seamless, stainlesssteel
pipe.
d. Pipe (optional) ASTM A106 Black seamless carbon steel pipe (AS4041).
This pipe will require chemical cleaning before use.

4.2 Pipe size

a. It is important for the lines between the main connections of the motor and
power unit to be as short as possible. For a normal hydraulic system, the total
pressure drop in the pressure and return lines must be not more than 5 percent
of the normal working pressure.
The following flow rates are recommended values and should not be exceeded.
Main lines 5.0 m/s
Drain lines 1.0 m/s
b. In certain systems, where very small compression volumes are required, higher
flow rates are acceptable. Refer to the contract specifications in these specific
cases.
c. Dimensioning of hose and pipe lengths between the DRAIN connections of the
motor and the power unit shall take place with due regard so that the total
pressure drop in the drain line of the motor must not exceed 1 bar. The pressure
drop through the power unit is approximately 0.5 bars.

4.3 Pipe clamps.

a. Pipes should be clamped with uniformly spaced clamps. The distance
between the clamps will not exceed two meters.
b. In addition, the pipes must be clamped. Immediately before and after a bend
and berfore a transition onto a hose.
c. The pipe clamps shall be secured to a stable and non-vibrating surface.
d. The pipe clamps must be of a type permitting a certain amount of axial and
radial motion in the clamped joint and have a good vibration absorbing
property.

4.4 Hoses
a. To avoid damage caused by vibrations it is appropriate for the power unit
and motor to be connected to pipes by means of hoses.
The hoses must be short and have the smallest possible diameter in order
to obtain a small compression volume. Allowance must be made for the
velocities, as listed under ”Pipe Sizes”. Allowance must also be made for the
minimum permissible bend radius as according to the data provieded by the
hose manufacturer.

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b. All hoses shall be cleaned using the ”CompriTec” cleaning system. The
method of a pull through rag with solvent is not recommended.

4.5 Welded Pipe systems.

Bosch Rexroth Mellansel recommend the use of non welded pipe systems such
as GS Hydro 37º flare and phosphated St52.4 cold drawn, seamless pipe. Welded
systems using black hot drawn pipe, require special attention to system cleanliness
and these systems should be avoided.
If welded and hot drawn pipe systems are used, then Bosch Rexroth Mellansels
warrantly obligations will be valid only if the following procedures are followed and
documented in writing and authorised Bosch Rexroth Mellansel representative.

4.5.1 Weld procedures.

a. Full penetration butt weld joints must be used on all applications. Socket
weld joints are not to be used due to contamination retention at the joints.
b. Root welds are to be made with the T.I.G. process with an Argon gas purge
to minimize slag build up and reducer chemical cleaning time.
c. DO NOT use M.I.G. weld, beacuse of difficulty in obtaining a ”leak free”
joint.
d. All welding to comply with Australian standards CB15.
e. Welding should take place close to the end of the pipe, so that the joint
can be thoroughly inspected and weld grinding inside the pipe can be
performed if required.
f. A protective plug should be inserted in the pipe before any cutting and
welding takes place, thus preventing further ingress of contaminants into
the pipe.
g. In the case where welds are located so that cleaning inside by grinding is
impossible, then the pipe should be filled with a protective Argon gas during
the welding procedure and then pickled.
h. In the case of welding stainless steel pipes, pickling is not usually necessary
when Argon protective gas is used during the whole welding process.

4.5.2 Chemical cleaning and oil flushing.

a. Systems that use black seamless carbon steel pipe must be chemically
pickled and neutralized in order to remove all scale and slag as in
accordance with AS 1627.4.
NOTE! Cold drawn seamless tube will also require pickling if it has been subjected
to welding or heating, otherwise it can be cleaned as detailed in 4.6 below.
Recommended pickling procedure is as follows
(for pipe assemblies done in workshops):
1. All surfaces thoroughly degreased with a vapour degreasing solvent,
such as Trichlor-ethylene or Chlorothene.
2. Commercially available derusting compound such as Sulphuric acid
should be used. A mix of 15% (by weight) of concentrated Sulphuric

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acid with hot water (70-90ºC). Surface oxides and mill scales can
be removed by continously agitating the pickling solution around the
surface and by circulating it around inside the pipe.
3. The pickling time should be between two to three hours. The pipe
should be lifted out of the solution at least three times every hour.
4. After pickling, the pipe should be washed in hot water (70-90ºC) for
approximately 15 minutes.
5. The pipe should then be neutralized in an alkaline solution of 0.5%
Caustic soda and 0.75% Trisodium Phosphate in hot water (70-90ºC).
Neutralization time in this solution should be 30 minutes.
6. After the pipe should be washed in hot water (70-90ºC) for
approximately 15 minutes.
7. The pipe should then be dried and anti rust compound such as Rust
Veto from E.F. Houghton and Co. quickly applied inside and outside the
pipe.
8. If the pipe is stored for any period of time, the ends must be covered
with plastic plugs or similar.

b. Pipe systems pickled in situ must be completely drained of pickling and

neutralizing fluids and the pipes must be flushed with mineral based hydraulic
oil, which is compatible with the main system oil.
This is to be performed by an external flushing system capable of developing a
minimum of 6.0 ms of oil velocity in the pipe, the main drive pump must not be
used.
A suitably sized filter should be installed during flushing to remove all
contamination, the filter should be checked regularly to ensure contamination
build up does not block the filter element.
Replace the filter elemens as necessary.
c. This flushing process will need to be repeated with clean oil, especially if the
flushing oil appears to be contaminated with chemical cleaning fluids. All
cleaning fluids must be thoroughly removed before the main system is
connected. The oil used for flushing must be discarded upon completion of the
flushing process. After the flushing process the pipes should be oiled with clean
oil and capped to prevent corrosion and contamination.
NOTE! Discarded oil is to be disposed of in a safe and environmentally sound
manner.

4.6 Cleaning non welded systems.

4.6.1 Pipes.
a. The pipes can be pre-cleaned at the workshop. After the ends are flared
and flanged they are to be blown with filtered and dry air of standards workshop
cleanliness level (ISO 8573-1:1991, 4/5/4. Filtration of 15 µm, dew poiont of +7ºC,
oil content of max 5 mg/m3). Plastic foam cleaning plugs are then blown through the
pipes (CompriTec system or equivalent).
b. The pipes are to be rust protected inside and out then capped at both ends
with protective plugs and or heat shrink plastic film.

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c. Once the pipes are site installed the overall system undergoes an oil flush in
order to reach the required cleanliness level for the system. See 4.8.

4.6.2 Hoses
a. Prior to assembly of fittings, the hoses are inspected for any visual external
or internal flaws, cuts or damage. The required hose length is then
measured, cut, cleaned and blown with filtered and dry air of standard
workshop cleanliness level. After this preparation, the fittings are crimped
on, to complete the assembly. Plastic foam cleaning plugs are blown
through the complete hose assembly.
b. Hoses are delivered to site with rust protection and with protective plastic
plugs in both ends.

4.7 Pressure testing.

a. All lines should be pressure tested to at least 1.5 times the maximum
working pressure and checked for leaks. The power unit and motor is to be
disconnected from the system during this test. The pressure test
should ideally take place prior to final flushing. Drain lines are not normally
pressure tested.

4.8 Final flushing.

a. On inital start-up of a new system a pressure filter should be installed in
the main return line, which is at the pump inlet on a closed loop system or
at the reservoir return on an open loop system. The flushing filter should be
sized to take the pumps’ maximum flow without excesseive pressure drop.
The main lines at the Hägglunds motor are to be connected together and the
entire system flushed at maximum flow until oil cleanlines level of ISO 4406
16/13 is achieved. The filter pressure drop should be monitored to assure
the filter is not becoming blocked, new elements should be installed if this
condition arises.
b. The motor case drain line should also be fitted with a filter to ensure that
any contamination from the drain line does not enter the reservoir.

5 Documentation
Witness documentation is required if welded pipe is used to qualify procedural
adherence.

Bosch Rexroth Mellansel AB, Pipework installation procedure, DD000*****/02.2015