Section 15

Hydraulic lines Page

Date
1
02.02

DIMENSIONING OF OIL LINES Rear mounted crane

To avoid large flow losses and high oil temperatu- With crane’s own oil tank and pump
res the lines between the pump, control valve flow up to 50 litres/min
and tank are recommended to be chosen (Inner
diameters ØD ) as follows. ØD • Pressure line 15 mm
• Return line 30 mm
• Suction line 38 mm

With separate oil tank and

Crane behind cab pump flow up to 50 litres/min
With crane’s own oil tank and pump flow up to
30 litres/min
• Pressure line 15 mm
• Return line 30 mm
• Pressure line 8 mm • Suction line 38 mm
• Return line 10 mm
• Suction line 25 mm With separate oil tank and
pump flow up to 100 litres/min.
With crane’s own oil tank and pump
flow up to 50 litres/min
• Pressure line 19 mm
• Return line 32 mm
• Pressure line 15 mm • Section line 50 mm
• Return line 30 mm
• Suction line 38 mm For all cranes with oil flow over
100 litres/min
With separate oil tank and • Pressure line 25 mm
pump flow up to 100 litres/min.
• Return line 38 mm
• Pressure line 19 mm • Suction line 63 mm
• Return line 30 mm
• Section line 50 mm Angled couplings, banjo couplings and other
types of couplings that restrict the flow should be
avoided.
All components must fulfill requirements
regarding working pressure etc.

In the case of a rear mounted crane with a separate oil tank, this must be located as near as possible, and if possible
higher than the pump. Recommended volume of the tank is 100 litres or more.
Section 4
Page
Date

11.05
Hydraulic lines
HYDRAULIC COUPLINGS Installation instructions
The fittings used for hydraulic connetions follow ISO
8434, i e the JIC system. – Secure the tube flare between the sleeve and the
fitting body nose by finger tightening the nut.
• 3 piece orginal design: fitting body and sleeve – Tighten using a torque wrench to get a secure and
connects 74°flare tube. tight metal to metal seal.
– If a torque wrench is not used the rule of thumb is
• The flared end of the tube is clamped between that, after the nut has been finger tightened, the nut
two surfaces:body nose and sleeve. The sealing should be further tightened a minimum 1/4 turn and
and gripping effect is maintained without any a maximum of 1/2 turn.
deformation.

• Sleeve design allows clearance between nut

Thread Tube Min. Max
and tube, aligns flare seat automatically, acts as UNF Dy kpm kpm
lockwasher, supports tube and dampens vibra-
7/16-20 6 1 1,5
ton. Sleeve does not rotate with nut eliminating 3/4-16 12 3,2 4,8
twisting of tube. 7/8-14 16 5,2 8

1 1/16-12 20 7,7 12
1 5/16-12 25 11,9
18

The nut turns on the sleeve at this point

Tube is not twisted

Sleeve leads the flared tube

Tube
UNF

Sleeve
Nut

Hose coupling
 Section 15
Hydraulic lines Page
Date
3
12.92

SUCTION LINE HIGH PRESSURE HOSE

By far the greatest part of operating trouble A pressure hose is built up of three main
derives from faults in the suction line: parts.
air entering the system due to faulty fitting.
C B A
Instructions:

1 Check that nipples and pipe ends are

free from burrs an have an even finish.
2 Rinse hoses and pipes with cleaning
liquid and compressed air.
3 Use oil resistant adhesive between
tube and hose. A Inner tube
4 The hose clamps should be drawn so B Reinforcement
tight that a noticeable waist appears on C Outer cover
the hose. The inner tubes of HIAB’s genuine hoses are
made of flexible, oil resistant synthetical rubber.

The reinforcement’s task is to take up pressure,

protect the inner tube and give the hose stability.
The reinforcement consisting of at least 2 braided
steel wires.

The outer cover’s job is to protect the reinforce-

ment from corrosion and from mechanical con-
Always use two hose clamps, screws tact. It is made of oil-and weather resistant
offset by half a turn. synthetical rubber.

5 Let the adhesive dry 2 hours. For all HIAB genuine pressure hoses the
If you follow these instructions and use following specifications apply.
HIAB genuine hoses the equipment will
operate faultlessly for a long period of Temperature range –40°C to +100°C
time. Burst pressure min 4 times the
allowed working pressure.
Couplings fitted to the steel
reinforcement
Section 4
Page
Date

11.05
Hydraulic lines
Data for high pressure hoses • Avoid twisting the hose.
Twisted hoses wear out quickly and there is a risk
that the fittings will loosen. All HIAB genuine hoses
are provided with a yellow reference line along the
length of the hose. The reference line facilitates
correct fitting.

d d D Work R Weight
press. Min Max
MPa bend Kg/m
min max max radius
mm tum mm mm mm mm
6.3 1/4 6.2 6.7 14.2 40 75 0.4
8 5/16 7.7 8.2 16.2 35 85 0.5
10 3/8 9.3 10.0 18.3 35 90 0.6

12.5 1/2 12.5 13.2 21.6 33 130 0.7

16 5/8 15.7 16.4 24.7 28 170 0.8
19 3/4 18.8 19.5 28.7 28 200 0.8 • Avoid to high temperatures.
Keep the hoses away from hot parts,such as
25 1 25.1 25.9 36.5 22 250 1.2 exhaust manifolds. If the hose cannot be drawn in
another way, the hose must be protected by means
of a shoulder of steel plating.

Fitting pressure hoses

• Avoid taut hoses.
Even if the hose ends do not move in relation to
each other the hose should be longer than the
distance between joining points. A hose under pres-
sure can be up to 6% shorter. • Avoid sharp bends.
Sharp bends weaken the hose quickly.The bend
radius depends on the hose diameter and oil pres-
sure. The hose manufacturer’s recommendations
should always be
observed.

• Avoid loops.
Use angled fittings instead which give a neater
installation and a shorter hose.

Hydraulic lines
HYDRAULIC STEEL PIPING
Wall thickness of a hydraulic pressure tube is
mainly determined by the working pressure. In
addition to this, the diagram below also takes into
account mechanical stresses and vibrations
during operation. The diagram is valid for:
Tensile strength 37 kg/cm 2
Safety factor 4
Cold drawn tubing intended for this
application
Section 15
Page
Date
5
12.92
How to use the diagram, example:
Inner diameter: 19 mm
Working pressure: 24 MPa
Assume a wall thickness of 2 mm, which gives
outer diameter 23 mm. The diagram gives wall
thickness 2,6 mm, therefore not acceptable. Now
assume wall thickness 3 mm giving outer
diameter 25 mm. The diagram gives a wall
thickness of 2,8 mm, thus acceptable.
Before final solution of the dimension the
minimum inside diameter is to be checked,
see recommendations at page 1 in this section.
 15
Hydraulic lines
Section
Page 6
Date 2007-02

CONSOLE MOUNTED CRANE

Like other materials hydraulic oil expands

when subjected to elevated temperatures. If
the oil is trapped this can lead to rupture in the Example of mounting
hydraulic system due to pressure increase.

If the system return line is open and connec-

ted to tank pressure rise due to high tempera-
ture is avoided.

A crane mounted on a detachable console ar-

ranged for easy detachment is fitted with quick
couplings in the return and pressure lines.

Older cooler and accumulator

Since the oil tank remains on the truck the oil

lines are blocked by the quick couplings. When
the detached crane is warmed up by sunshine
there is a risk that a system component will
rupture. The components most exposed are
oil coolers, CombiDrive spool positioners and
return passages in valves.
In order to avoid this it is recommended to fit
a membrane accumulator in the return line to
take care of the expanding oil.

Membrane accumulator as is mobil monted

don’t require certificate.

All assembly and necessary new oil lines are

to be provided by the local body builder.
 Section 15
Hydraulic lines Page
Date
7
11.02

Special valve for vechicles with detachable

crane

Function
The valve is used in order to protect the pump and the
control valves against overloading and to ensure a
controlled max pressure in the return line when
attaching and removing the crane which may cause
faulty connection of the quick couplings.
This special valve will safeguard pumps and valves
against breakdowns.
Technical information
The pilot valve (item 1) is adjustable 20-40 MPa and
factory pre-set to 35 MPa.
This value can be adjusted. The valve, shall, however,
always be appr. 3 MPa higher than the max. working
pressure of the crane.
The pressure sensor (item 2) is adjustable to 1-5 MPa.
The pilot valve (item 1) will only be activated from the
pump side, the high-pressure side. The pressure
sensor (item 2) can be activated both from the pump
and return side.
Both the pilot valves (1) and (2), unload the logic
element at activation and make a connection from
P⇒ T with a ∆ρÿof appr. 1 MPa, independant of
adjusted pressure on the pilot valves. This connection
is going on as long as it is an oil flow through the
logic element (3)!
The valve won’t return to its starting point until the
pump has been stopped and the flow through the logic
element has been shut off. After that the quick
couplings between the carrier and crane can be
controlled with reference to the fact that the catch has
been made in the right way.
The pump pressure will be measured at connection (M)
Starting
The valve shall be connected acc. to the scheme
below. Start the pump and vent the logic element by
opening the venting screw (A) some turns. When all air
is evacuated, shut off the venting screw again and the
valve is ready for operation.

(1) (M)
(ISO G 3/4)
T

(ISO G 3/4)
(A) P

(2)

T1
(ISO G 1/4)
All assembly and
necessary new oil
lines are to be
provided by the
body builder.