Hydraulics plays a central role in the assembly of machines and systems. Wherever high forces must be transmitted precisely, reproducibly, and safely within a confined space, hydraulic systems are the first choice. For companies like A & P Industriemontage, this means the utmost care in planning, piping, assembly, commissioning, and service. Errors or contamination have a direct impact on performance, service life, and safety—and that is precisely why hydraulics is one of the most demanding disciplines in complex plant installations.
Hydraulics provide the power required by modern production and machine tools. They enable precise movements, high operating pressures, and reliable process flows—often around the clock.
Hydraulic drives deliver high forces in a compact design. Presses, cylinders, clamping devices, and machine tools often operate at pressures between 80 and 300 bar—and in some specialized applications, even significantly higher. This performance range often cannot be achieved cost-effectively with electric or pneumatic systems.
The most common hydraulic functions include:
This makes hydraulic systems essential for machine relocation, disassembly and reassembly, retrofits, and modernization.
In production lines, hydraulic power units, valve blocks, servo valves, and cylinders control highly dynamic movements. Precision and cleanliness are particularly important during assembly—especially in injection molding machines, transfer lines, and special-purpose machines.
Proper mechanical and electrical connections of all hydraulic components are essential for safe system operation.
A hydraulic power unit provides the flow rate and system pressure. The tank, pump, filter, pressure relief device, and valves form a single unit. Important considerations during installation:
A pressure relief valve that is not set correctly increases the risk of damage and uncontrolled movements.
Cylinders and motors must be installed in alignment, subjected to the correct static and dynamic loads, and mounted to minimize vibration. Valve blocks must be clearly labeled, securely grounded, and have clearly marked wiring to prevent mix-ups.
Errors in pipe installation are among the most common causes of leaks. It is important to note that:
The quality of the piping determines the reliability of the entire hydraulic system.
When bending and screwing pipes, no forces should act on the components. Stress can lead to cracks, microleaks, or fatigue over time. Pipe clamps prevent vibrations and protect pipes from abrasion.
Key criteria:
High points in the system require vent screws to ensure that air pockets do not interfere with the test run. Likewise, clamp spacing must be selected according to the manufacturer’s specifications to minimize resonance and vibration.
A structured commissioning process is critical to safety, service life, and trouble-free operation.
New lines or components must be flushed before the system is put into operation. This process removes metal shavings, production residues, and dirt particles. The system is then filled with filtered oil, and all consumers are bled.
During the test run:
Clear documentation of the measured values is essential for future service.
Depending on their area of application, hydraulic systems require an inspection in accordance with DGUV standards. These include:
Hydraulic systems operate at high pressures—which is why safety is the top priority.
Check valves, shut-off valves, and pressure relief devices prevent dangerous movements when malfunctions occur or lines are damaged.
Pipes must be rated for the maximum system pressure—including a margin for pressure surges. An incorrectly adjusted pressure relief valve can damage components or cause uncontrolled acceleration of movement.
More than 70% of all hydraulic failures are caused by contaminated oil. Regular oil maintenance and filtration significantly extend the service life of pumps, valves, and cylinders.
A & P Industriemontage provides hydraulic services worldwide—from maintenance to modernization.
Typical responsibilities:
A retrofit improves energy efficiency, process reliability, and plant availability—without the need for a complete replacement.
Systematic fault diagnosis allows for the quick identification of typical problems such as pressure loss, overheating, or erratic movements.
When relocating machinery, working with hydraulic systems is particularly challenging.
The system will operate without problems after the move only if the piping, valve systems, and electrical connections are precisely reconstructed.
A & P performs hydraulic work worldwide—in Europe, Asia, North America, and beyond. The combination of mechanical, electrical, and hydraulic engineering makes the company a reliable partner for complex plant installations.
Specialists from various trades work together as a well-coordinated team—a key advantage when dealing with complex systems.
A & P supports projects ranging from small and medium-sized businesses to global industrial conglomerates.
Having all services provided by a single source minimizes coordination efforts and speeds up project workflows.
Professional hydraulic installation is a key factor for success in industrial installation. From piping to commissioning to service, the quality of every single step determines safety, system availability, and process stability. With in-depth expertise, structured processes, and global experience, A & P Industriemontage ensures that hydraulic systems operate reliably—today and in the future.
Proper hydraulic installation includes the tension-free routing of all lines, the correct selection of hoses and fittings, the clean installation of cylinders and valve blocks, and the low-vibration mounting of all assemblies. This is complemented by precise electrical connections, testing of pressure and tank lines, clear labeling, and complete technical documentation. Errors during assembly often lead to leaks, pressure loss, or premature wear—which is why clean, structured execution is crucial.
Commissioning begins with filling and flushing the system, followed by venting all consumption points and pipeline sections. This is followed by a safe test run at reduced pressures before pressure relief valves and flow rates are set correctly. Finally, the system is checked for leaks, temperatures are monitored, sensors are tested, and all setpoints are documented. Proper commissioning is crucial for the operational safety and service life of the system.
Pressure loss is usually caused by internal leaks in valves or cylinders, contaminated hydraulic oil, or incorrect pressure settings. Jerky movements often indicate air in the system, defective damping elements, or clogged filters. During troubleshooting, measuring devices are connected to test ports, return flow rates are measured, valves are tested individually, and oil conditions are analyzed. This systematic analysis saves time and prevents the unnecessary replacement of components.
Oil maintenance is one of the most important factors in ensuring the reliability of hydraulic systems. Over 70% of failures are caused by contaminated oil. Regular filtration, oil changes, particle measurements, and flushing of new or modified lines significantly extend the service life of pumps, valves, and cylinders. Thorough oil maintenance should always be performed, especially when machines are relocated or modified.
When relocating machinery, hydraulic lines must be properly disconnected, labeled, and sealed with plugs. Before reassembly, new lines and components are flushed, bled, and inspected. After installation, a complete commissioning process is performed, including a pressure test, valve adjustment, and documentation. Professional handling prevents oil leaks, contamination, and damage to power units, cylinders, and valve blocks.
At A&P Industriemontage, we support companies worldwide in the installation and commissioning of complex industrial plants. With our expertise and comprehensive range of services, we ensure efficient and safe production processes. Trust in our many years of experience, and let’s work together to successfully implement your projects.