Service, maintenance and hose crimping

On-site service

Our service team responds to the breakdown on site: fault finding without dismantling and transporting the machine, hose and fitting replacement, seal renewal, pressure and speed adjustment. Urgent jobs are done in-house, by our own team; because our parts stock is at our company headquarters in Denizli, the waiting time does not depend on procurement.

Mobile hose crimping

With our service vehicle, which carries a crimping machine, we cut the hose to length at the breakdown site, crimp its fittings and install it. The construction machine, press line or vehicle-mounted equipment is back in operation where it stands; the time lost going to and from a workshop for a hose disappears. In our workshop we produce hose assemblies in series and carry out piping installation. Besides hydraulic hoses, industrial hoses such as food, chemical and concrete hoses are also in stock.

Predictive maintenance: seeing the fault before it happens

Our aim is not to wait for the machine to fail and stop, but to keep production running without unplanned downtime. In hydraulic and pneumatic systems most faults do not appear suddenly: pump wear shows itself in vibration, seal and valve leakage in heating, filter and oil degradation in the contamination level, weeks in advance. With our predictive maintenance instruments we measure these symptoms, compare the values with earlier measurements and time the intervention to coincide with a planned stop of the machine.

What we measure

• Vibration monitoring: vibration measurement on the pump, motor and coupling. The rise of the value over time reveals bearing wear, coupling misalignment and internal pump wear before failure.
• Air leak detection: locating leak points on compressed air lines by the ultrasonic method. A leak means the compressor is running for nothing; the points found are tagged and reported.
• Oil viscosity analysis: when the viscosity of the oil deviates noticeably from its nominal value (e.g. ISO VG 46), the oil has either degraded or been mixed with the wrong oil; this directly shortens pump and seal life.
• Oil contamination analysis: measuring the solid particle and water content of the oil. The contamination level is expressed with the ISO 4406 cleanliness code and compared with the limit the system requires (systems with proportional and servo valves need cleaner oil).
• Temperature and pressure check: deviation from normal operating values indicates internal leakage and loss of efficiency.

Oil flushing (system flushing) and oil change

In a contaminated system, changing the oil alone is not enough: the particles left in the pipes, the hoses and the bottom of the tank contaminate the new oil to the same level in a short time. In flushing, the system is flushed at high flow, with turbulent flow, by an external circulation unit with fine filters; once measurement confirms that the target cleanliness level has been reached, the new oil is filled through a filter. The same flushing is applied to newly built and overhauled systems before commissioning, so that swarf and weld residue left from assembly do not reach the pump at first start. In an oil change, the filter elements, the breather filter and tank cleaning are part of the same job.

Periodic maintenance and service records

Waiting for the breakdown is the most expensive maintenance method. We draw up a maintenance plan according to the operating conditions of the machine and record every visit in our service management system: the work done, the parts replaced, the values measured. The time of the next maintenance is planned from this record; a fault that recurs on the same machine also becomes visible this way. We follow up the maintenance of the cylinders and power units we manufacture in the same way.

What is checked in periodic maintenance

• Oil level, color and contamination; oil and filter change when needed
• Clogging indicators of the suction, pressure and return filters
• Outer surface of the hoses, fitting connections and traces of leakage
• On cylinders: rod surface, wiper seal and internal leakage
• Operating pressure, relief valve setting and speed values
• Accumulator pre-charge pressure, oil temperature and cooler
• Pump and motor noise, vibration, coupling and fasteners

Hose service life

Even if a hydraulic hose looks sound from the outside, its inner layer ages over time. According to the DIN 20066 recommendation, the service life of a hose assembly, including storage, should not exceed six years. A hose showing crushing, abrasion marks, cracks at the fitting, bulging or sweating is replaced without waiting for that period. The burst of a hose under pressure can cause an occupational accident; that is why we treat hose replacement as part of the maintenance plan.

Workshop repair and overhaul

• Hydraulic cylinder overhaul: seal replacement, rod and tube inspection
• Overhaul of power units, presses and lift systems
• Maintenance and repair of hydraulic and pneumatic machine lines
• Manufacturing of the required parts in our turning workshop

When reporting a fault

Please send the type of machine, the symptom of the fault and, if possible, a photo or a short video. For a hose replacement, the code on the label of the old hose and its length speed up our work.