Hydraulics play a central role in industrial assembly. Hydraulic systems are the first choice wherever high forces need to be transmitted precisely, reproducibly, and safely in confined spaces. For companies such as A & P Industriemontage, this means taking the utmost care in planning, piping, assembly, commissioning, and service. Errors or contamination have a direct impact on performance, service life, and safety—which is precisely why hydraulics is one of the most demanding trades in complex plant assembly.
Hydraulics provide the power required by modern production and machine tools. They enable precise movements, high working pressures, and reliable processes—often around the clock.
Hydraulic drives enable high forces with a compact design. Presses, cylinders, clamping devices, and machine tools often operate at pressures between 80 and 300 bar—and in some specialized areas, even significantly higher. This performance range often cannot be achieved economically with electric or pneumatic systems.
The most common hydraulic functions include:
This makes hydraulic systems essential for machine relocation, dismantling and reassembly, conversions, and modernization.
In production lines, hydraulic units, valve islands, servo valves, and cylinders control highly dynamic movements. Precision and cleanliness are particularly important during assembly in injection molding machines, transfer lines, and special-purpose machines.
Professional mechanical and electrical connection of all hydraulic components is a basic requirement for safe system operation.
A hydraulic power unit provides the volume flow and system pressure. The tank, pump, filter, pressure limiter, and valve technology form a single unit. Important aspects during installation:
An incorrectly adjusted pressure relief valve increases the risk of damage and uncontrolled movements.
Cylinders and motors must be mounted in alignment, loaded correctly in terms of static and dynamic forces, and fastened in a low-vibration manner. Valve blocks require clear labeling, secure grounding, and unambiguous pipe labeling to prevent confusion.
Errors in pipe laying 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 be exerted on the components. Over time, tension can lead to cracks, micro-leaks, or fatigue. Pipe clamps prevent vibrations and protect pipes from abrasion.
Important criteria:
High points in the system require vent screws to ensure that the test run is not affected by air pockets. Clamp spacing must also be selected according to the manufacturer’s specifications in order to minimize resonance and vibration.
A structured commissioning process is crucial for safety, runtime, and trouble-free operation.
New pipes or components must be flushed before the system goes into operation. This removes metal chips, production residues, and dirt particles. The system is then filled with filtered oil and all consumers are vented.
During the trial run, the following will be done:
Clear documentation of the measured values is essential for later servicing.
Depending on their area of application, hydraulic systems require DGUV-compliant testing. This includes:
Hydraulic systems operate at high pressures, which is why safety is the top priority.
Check valves, shut-off valves, and pressure relief valves prevent dangerous movements when faults occur or pipes are damaged.
Pipes must be designed for the maximum system pressure, including reserves for pressure surges. An incorrectly adjusted pressure relief valve can damage components or cause uncontrolled acceleration of movements.
Over 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 tasks:
A retrofit improves energy efficiency, process reliability, and plant availability—without having to purchase a completely new system.
Systematic fault diagnosis allows typical problems such as pressure loss, overheating, or uneven movement to be quickly identified.
When moving machines, handling hydraulic systems is particularly challenging.
Only if the piping, valve technology, and electrical connections are reconstructed exactly will the system run smoothly after the move.
A & P carries out hydraulic work worldwide—in Europe, Asia, North America, and beyond. The combination of mechanical engineering, electrical engineering, and hydraulics makes the company a reliable partner for complex plant installations.
Specialists from different trades work as a well-coordinated team—a decisive advantage when it comes to complex systems.
A & P supports projects ranging from small and medium-sized enterprises to global industrial corporations.
All services from a single source minimize interfaces and accelerate project processes.
Professional hydraulic installation is a key success factor in industrial assembly. From piping and commissioning to servicing, the quality of each individual step determines safety, plant availability, and process stability. With in-depth expertise, structured processes, and global experience, A & P Industriemontage ensures that hydraulic systems work reliably—today and in the future.
Professional hydraulic installation includes tension-free laying of all lines, correct selection of hoses and screw connections, clean installation of cylinders and valve blocks, and low-vibration fastening of all assemblies. In addition, there is precise electrical connection, testing of pressure and tank lines, clear labeling, and complete technical documentation. Errors in installation 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 consumers and pipe sections. This is followed by a safe test run at reduced pressures before pressure relief valves and volume flows are set correctly. Finally, leaks are checked, temperatures monitored, sensors tested, and all setpoints 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 dirty filters. During fault diagnosis, measuring devices are connected to test connections, return flow rates are measured, valves are checked individually, and oil conditions are analyzed. Systematic analysis saves time and prevents unnecessary replacement of components.
Oil maintenance is one of the most important factors for the reliability of hydraulic systems. Over 70% of failures are caused by contaminated oil. Regular filtration, oil changes, particle measurements, and flushing new or modified lines significantly extend the service life of pumps, valves, and cylinders. Thorough oil maintenance should always be carried out, especially when machines are relocated or modified.
When moving machines, hydraulic lines must be cleanly disconnected, labeled, and sealed with sealing plugs. Before reassembly, new lines and components are flushed, vented, and tested. After assembly, a complete commissioning process is carried out, including pressure testing, valve adjustment, and documentation. Professional handling prevents oil loss, contamination, and damage to units, cylinders, and valve blocks.
At A&P Industriemontage, we support companies worldwide in the assembly and commissioning of complex industrial plants. With our expertise and comprehensive services, we ensure efficient and safe production processes. Trust in our many years of experience and let us work together to successfully implement your projects.
