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Hydraulic system service and diagnostics

Service
and diagnostics for hydraulic systems

Diagnostics, fault removal and continuous maintenance of hydraulic systems in machines, production lines, and industrial installations across various sectors.

Service and diagnostics

Manufacture hydraulic cylinder
Hydraulic system service and diagnostics

Service and diagnostics

Hydraulic pump reconditioning

Reconditioning of hydraulic pumps

Restoring the efficiency, performance, and operating parameters of Rexroth hydraulic pumps used in industry.

Recondition a Rexroth pump

Manufacture hydraulic cylinder
Hydraulic pump reconditioning

Recondition a Rexroth pump

Hydraulic system service and diagnostics

Service of hydraulic cylinders

Comprehensive hydraulic cylinder service, including assessment of technical condition, component regeneration, and restoration of proper operating parameters.

Cylinder service

Produce hydraulic cylinder
Hydraulic system service and diagnostics

Cylinder service

Hydraulic oil filtration

Filtration
and oil system service

Filtration of hydraulic oil, cleaning of reservoirs, and preparation of the system for further operation, restoring the required cleanliness class of the
medium.

Hydraulic oil filtration

Produce hydraulic cylinder
Hydraulic oil filtration

Hydraulic oil filtration

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Service and diagnostics for hydraulic systems

Diagnostics and service of hydraulic systems

Precise diagnostics hydraulic systems

We conduct diagnostics of hydraulic power units in machines and industrial installations,
analyzing causes of failures, performance drops, and improper operation of hydraulic systems. We use advanced STAUFF diagnostic devices that enable measurement of pressure, flow, and temperature at multiple installation points using flow turbines and pressure sensors, allowing precise determination of system operating condition and problem source.

Mobile service and repairs hydraulic power units

Hydraulic power unit service is performed by mobile, specialized diagnosticians
and service technicians experienced in working with industrial installations.
Thanks to service vehicles equipped with measuring and diagnostic equipment,
swift response to failures and effective repair of hydraulic power units as well as restoration of factory parameters in machines, technological installations, and production lines are possible.

Hydraulic system service and diagnostics

Fixed hourly rate

Billing at the end of each month
based on the agreed hourly rate.

Agreed response time

Guaranteed action initiation time, tailored to maintenance needs.

Action planning

Service work schedule adapted
to the operating and production cycle of the installation.

Intervention report

Service protocol issued each time after completed intervention, including hourly billing.

Service care within the contract

Cost predictability service

Service care within the contract allows maintaining hydraulic power units under constant service supervision and better planning of industrial installation maintenance costs. Cooperation is based on an agreed hourly service work rate, enabling predictable service budget planning and reduction of costs related
to unplanned failures.

Work planning and maintenance support

Continuous service cooperation allows planning maintenance
and servicing activities in an organized manner, adapted to the plant's operating cycle. This reduces the risk of hydraulic power unit failures and ensures continuity of operation of machines and industrial installations, directly impacting production stability.

Modernization of hydraulic systems

Modernization hydraulic installations

We carry out modernizations of hydraulic systems in cases where the existing installation no longer meets performance, operational, or safety requirements. Thanks to our engineering support and in-house design office, we are able to analyze system operation, design modifications, and select
appropriate technical solutions for hydraulic systems used in industry.

Reliability improvement hydraulic power equipment

The modernization includes reconstruction of system sections, replacement of worn components, and optimization of installation operating parameters. With design support, it is possible to adapt hydraulic systems to the actual working conditions of machines and to achieve a lasting improvement in the reliability and stability of hydraulic systems operation in industrial plants.

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Rebuilding of Rexroth hydraulic pumps

Pump diagnostics Rexroth hydraulic

After delivering the pump to our service center, we perform diagnostics of Rexroth hydraulic pumps aimed at assessing the technical condition and determining the necessary scope of refurbishment. The pump is connected to a hydraulic pump test bench where basic operating parameters and the wear level of working components are checked. Based on the measurements taken, it is possible to determine whether the pump qualifies for refurbishment and which components require replacement or repair to restore factory specifications.

Pump reconditioningRexroth axial piston pumps

We specialize in the refurbishment of Rexroth hydraulic pumps, particularly axial piston pumps used in industrial machines and installations. The refurbishment process includes replacement of worn working components and precise adjustment of the pump to restore the factory parameters.

Testing and performance characteristics pump operation

After completing the refurbishment, the pump undergoes testing at the test bench, enabling verification of its operation under controlled conditions. The test bench allows determination of the hydraulic pump's performance characteristics, and the client receives a printout and report of the tests confirming the operational parameters of the refurbished axial piston pump.

Most frequently reconditioned models Rexroth hydraulic pumps
Hydraulic system service and diagnostics
Rexroth hydraulic pump

Pump reconditioning

Rexroth A4VSO

40 / 71 / 125
Rexroth hydraulic pump

Pump service

Rexroth A10VSO

18 / 28 / 45 / 71 / 100
Rexroth A7VO hydraulic pump

Pump repair

Rexroth A7VO

55
Rexroth A2FO hydraulic pump

Pump diagnostics

Rexroth A2FO

23 / 45

Frequently asked questions about hydraulic pump problems

My Rexroth A4VSO pump is losing performance – what could be the cause?

A drop in efficiency of a Rexroth A4VSO pump can result from wear of pump components, but often the cause is also leaks in the system, a contaminated filter, or improper operation of the relief valve. Only diagnostics and measurement of operating parameters can determine whether the problem concerns the pump itself and if regeneration of the Rexroth hydraulic pump is necessary.

Rexroth A10VSO pump does not reach proper pressure– what to check?

In Rexroth A10VSO pumps, insufficient pressure may result from incorrect pump regulator settings, issues
with the LS system, or hydraulic elements located downstream of the pump such as relief valves or flow control valves. In many cases, adjustment or elimination of problems in the installation is sufficient, and hydraulic pump servicing is only necessary when actual wear of pump components occurs.

Rexroth A11VO pump operates noisily or vibrations occur – what does it mean?

Noise or vibrations in Rexroth A11VO pumps can be caused by cavitation, air entrainment in the system, an undersized suction line, or a clogged filter. Initially, the operating conditions of the pump in the hydraulic system are checked, and only afterwards is it assessed whether repair or refurbishment of the hydraulic pump is required.

Rexroth A4VG pump overheats during operation – does it always indicate damage?

Elevated operating temperature of the Rexroth A4VG pump may result from incorrect pump settings, operation under excessive load, or flow throttling through hydraulic system components. An analysis of operating parameters helps determine whether the cause is the installation or the pump itself and if Rexroth hydraulic pump servicing is necessary.

Can the Rexroth A7VO pump be tested after repair or refurbishment?

Yes. Rexroth A7VO pumps after service or refurbishment can be connected to a test bench where operating parameters and pump characteristics are verified. The client receives a printout and a test report confirming proper pump operation.

How much does the refurbishment of the Rexroth A4VSO pump cost?

The cost of refurbishing a Rexroth A4VSO pump depends on the wear level of its working components. During diagnostics, the pump is disassembled and individual parts—such as the cylinder barrel, pistons, distribution plate, swash plate, bearings, or regulator components—are assessed for wear and suitability for further use. Refurbishment involves replacing specific worn elements rather than entire assemblies "blindly," allowing the client to know exactly what has been replaced and the actual cost of restoring the pump to factory parameters.

Why does the Rexroth hydraulic pump lose pressure during operation?

Pressure loss in Rexroth pumps can result from wear of pump components, but often the cause is leaks
in the system, damaged valves, or incorrect pump regulator settings. Thorough diagnostics allow determining whether the issue concerns the pump or hydraulic system components.

How to check the Rexroth A10VSO pump before installation in the machine?

The most reliable method is testing the Rexroth A10VSO pump on a test bench, where its performance, pressure, and operating characteristics can be verified. Such a test confirms pump parameters and excludes problems before reinstalling it in the hydraulic system.

Is it necessary to disassemble the pump immediately to perform initial diagnostics?

No, it is not necessary. It is advisable first to describe the failure symptoms and suspicions by phone to the diagnostician, and if needed, arrange diagnostics at the client's facility, during which the service can connect measurement equipment before and after the pump in an operating system and determine its operating parameters under load without dismounting the suspected unit.

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Service of hydraulic cylinders

We service hydraulic cylinders based on
the technological processes used by OEM manufacturers.

Scope of hydraulic cylinder service

Hydraulic cylinder service includes, among others:

disassembly and technical condition assessment all components,

reconditioning or manufacture of a new piston rod
(grinding, re-chroming and grinding to nominal size — where technically
and economically justified),

honing the cylinder or replacing the tube with a new one,

inspection and reconditioning or remanufacture of the rod gland,

fabrication and replacement of all seals and elements guiding the piston rod,

replacement of bearings and mounting components,

leak and functional tests,

preparation of external surfaces (sandblasting, priming,
hardened external coating selected for operating conditions).

Refurbished hydraulic cylinder leaves the facility as a fully functional component, ready for further use.

Reconditioning is an alternative to purchasing a new hydraulic cylinder, especially in the case of non-standard designs.

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Filtration and oil service of systems

Hydraulic oil filtration on-site

We offer mobile hydraulic oil filtration directly
at the customer's site. We have filtration units, which allow us to perform hydraulic oil service in industrial plants, at machines, production lines
and installations operating based on hydraulic systems.

Depending on technical conditions, filtration is conducted either in a closed circuit or after pumping the oil into a separate tank, which allows for thorough cleaning of the tank and re-filtering of the medium before filling the system again. This service effectively reduces the amount of contaminants, improves the operating conditions of the hydraulic oil, and decreases the risk of failure of pumps, valves, and hydraulic cylinders.

Oil service hydraulic systems
and selection of the appropriate medium

We provide comprehensive hydraulic oil service for hydraulic systems, including hydraulic oil replacement, filter cartridge replacement, and technical support in selecting the appropriate operating fluid. We offer oils from reputable manufacturers,
and our engineering team selects the oil according to the actual operating conditions of the system, ambient temperature, loads, and the specifics of the given application. In many cases, the oil previously used is not the optimal solution, so the correct selection directly affects the durability of components, system operational stability,
and reduction of operating costs.

Regular hydraulic oil changes and correctly performed hydraulic system oil maintenance are among the simplest ways to extend the service life of the entire installation.

Oil analysis hydraulic
and cleanliness class control

Already during filtration, we are able to determine the oil cleanliness class, the level of contamination with solid particles, as well as monitor
the water content and medium temperature. We use the STAUFF ICM particle counter, which allows us to carry out hydraulic oil filtration to the required cleanliness class.

Additionally, we perform sampling of hydraulic oil for testing at an external accredited laboratory, where other physicochemical properties of the medium are also analyzed.

Hydraulic oil filtration

Selection of hydraulic filters
and replacements 1:1

In hydraulic power units, proper filtration of hydraulic oil is crucial for protecting pumps, valves, and hydraulic cylinders.

Selection of a hydraulic filter depends on the installation location, operating pressure, oil flow, and the required cleanliness class of the medium. In practice, various types of filters are used, including hydraulic suction filters, hydraulic pressure filters, return filters,
in-line filters, and oil tank breather filters. In demanding installations, duplex filters are also employed, allowing replacement of the filter element without stopping the operation of the hydraulic system.

We provide selection, sale, and replacement of hydraulic filters for industrial systems and machines operating based on hydraulic power. We supply both original OEM hydraulic filters and replacements 1:1 with matching technical and filtration parameters. Our offer includes solutions from manufacturers such as HYDAC, Parker, Donaldson, Bosch Rexroth, and MP Filtri, as well as high-quality compatible replacement components for their filtration systems.

When selecting, we analyze, among others, the filter type, filtration accuracy
in microns, flow rate, operating pressure, bypass valve parameters, and seal type. This allows us to provide the customer with the appropriate hydraulic filter for the machine
or hydraulic system—both during on-site service and via courier shipment based on the filter's nameplate or installation data.

Which hydraulic equipment do we service?

rexroth pump

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