Our achievements

At DV Hydraulics, we recently carried out a complete overhaul and extensive testing of a Hägglunds SP500 hydraulic pump on our test bench. From initial start‑up to heavy load testing, this unit is once again ready for many years of reliable operation.

Hägglunds pumps are typically used in heavy industrial applications where high torque, robustness and operational reliability are critical.

Complete Overhaul According to OEM Specifications

The performed overhaul included:

• Complete disassembly and inspection of all internal components

• Replacement of the complete drive mechanism

• Restoration and correct zero‑point adjustment of the pump

• Inspection and adjustment of all valves

• Reassembly according to OEM guidelines

Each step was carried out with a strong focus on accuracy and durability, ensuring the motor once again meets its original performance specifications.

Extensive Testing Under Realistic Load Conditions

After the overhaul, the Hägglunds SP500 was tested on our test bench, specifically designed for heavy hydraulic components:

• Tested under loads exceeding 300 bar

• Torque during testing up to 3000 Nm

• Stability and performance verified under realistic operating conditions

Thanks to this test capacity, we can easily test large pumps and motors well above 500 cc, both functionally and under full load.

This provides maximum assurance after overhaul.

Reliability Before Commissioning

Our test bench was built with one clear objective: to guarantee reliability before the pump or motor is returned to service.

Only after successful testing is the unit released — in this case, following the application of a new protective paint coating.

Do you have a pump that requires overhaul or an upgrade?

Contact our team via our contact page.

DV Hydraulics designed and built two hydraulic power units for a petrochemical application, intended for integration into an existing installation as part of a retrofit project. Both units were fully engineered to exact installation dimensions, ensuring smooth integration and minimal downtime on site.

The hydraulic systems were developed with a strong focus on reliability, safety and ease of maintenance, and were recently factory acceptance tested together with the customer in our workshop (FAT). After delivery, the units will be installed and commissioned by our service technicians on site.

Thanks to careful component selection and a well-considered layout, these units are suitable for long-term operation in demanding petrochemical environments.

Technical specifications of the units:

• Robust external gear pumps

• ISO valves used throughout the entire installation

• FKM seals, suitable for chemically aggressive fluids and elevated temperatures

• FKM accumulators supplied separately, allowing safe handling and installation on site

• Manual hand pumps provided for emergency operation

• Key-lockable flow control valves, preventing unauthorized adjustments

• Built according to exact installation and connection dimensions for retrofit

• Painted according to customer paint specifications

• Design focused on operational reliability, safety and easy serviceability

By combining controlled flow regulation, emergency operation capability and proven components, these hydraulic units ensure safe and stable performance, even under critical process conditions.

The systems were delivered plug-and-play, including full technical documentation and FAT reports.

Looking for a reliable partner for hydraulic installations in the petrochemical or heavy-industry sector? Contact DV Hydraulics and discover how we can support you with robust hydraulic solutions.

DV Hydraulics designed and built a hydraulic power unit for a discharge function in the fibre cement industry, intended for the controlled material discharge via a tipping hopper onto a conveyor belt. This hydraulic installation was fully engineered and manufactured to measure, with a focus on simplicity, robustness and a short delivery time.

By using standardized and normalized components, the system is reliable, easy to maintain and suitable for long-term operation in demanding industrial production environments.

Technical specifications of the installation:

• 5.5 kW electric motor

• 14 cc external gear pump

• Nickel-plated manifold block for increased corrosion resistance

• NG06 valves compliant with ISO standards

• Return and breather filters for safe and efficient maintenance

• Hydraulic cylinder with 100 mm bore, 60 mm rod and 800 mm stroke, equipped with load-holding valves

• Hydraulic hoses with abrasion protection for extended service life

• Design focused on long service life and ease of service

By equipping the hydraulic cylinder with load-holding valves, the load can be moved in a controlled and safe manner during the discharge process. This hydraulic power unit was delivered plug & play with complete technical documentation.

Do you have a project where you are looking for a reliable partner in hydraulic installations? Contact us and discover how DV Hydraulics can support you.

DV Hydraulics carried out a retrofit of a 10,000-ton press with an advanced servo pump system. Originally built with a conventional hydraulic system, this press was upgraded in 2013 by DV Hydraulics to an energy-efficient installation featuring servo pumps.

The project included not only the hydraulic upgrade but also the complete control system and safety features around the press, including loading and unloading, and pre- and post-press checks.

The result: a powerful, precise, and reliable solution that meets the highest industrial standards. The press operates in two quadrants and uses a servo pump system for highly efficient drive performance. This retrofit is a prime example of innovation and sustainability in heavy industry, particularly in control and safety.

Main specifications of the press:

• Press force: 10,000 tons

• Number of cylinders: 2 units, bore 1,215 mm – stroke 630 mm

• Synchronization: servo pump control, accuracy < 0.05 mm

• Closing speed: 400 mm per minute

• Existing frame: reused

Main specifications of the hydraulic installation:

• Operating pressure: 450 bar

• Maximum flow for opening/closing: 1,000 liters per minute

• Medium: Hydraulic oil VG46

• Servo pump system: DV Hydraulics’ first servo pump project (2013)

• Control: Closed-loop for synchronization and speed

• Energy efficiency: Retrofit to servo pump technology – significant energy reduction

Control system specifications:

• Complete control and safety: Siemens components

• PLC: Siemens S7 series

• Functions: Loading and unloading, pre- and post-press checks

• Safety: Integrated safety logic

This retrofit combines power, precision, and energy efficiency in one solution.

Thanks to servo pump technology and Siemens control, this system is ideal for demanding industrial applications where reliability and accuracy are critical.

Do you have a challenging project with complex motion control?

At DV Hydraulics, we specialize in designing, building, and retrofitting hydraulic installations and presses that deliver top performance with a minimal ecological footprint.

Our servo pump technology provides powerful, precise, and energy-efficient performance – a smart choice for your business and the environment.

Contact us – we’ll be happy to provide a tailor-made solution.

DV Hydraulics carried out a complete refurbishment of a 600-ton hydraulic press by integrating a highly energy-efficient servopump system. This 50-year-old press was fully overhauled mechanically and transformed into a modern, safe, and extremely energy-efficient installation.

The original hydraulic components were replaced by an advanced servopump system, new cylinders, and a completely renewed control and safety system.

The result: a powerful, quiet, and precise press that meets the strictest industrial requirements — including full new CE marking.

Project scope

The refurbishment covered both the hydraulic modernisation and the complete control and safety systems. The press was also mechanically overhauled, equipped with new main cylinders, and fitted with additional safety components compliant with PL e. The machine is now a future-proof installation offering efficiency, precision, and operational reliability.

Key results

• Energy consumption drastically reduced: from a constant 30 kW to an effective 2.8 kW → 91% energy reduction

• Significantly reduced noise level thanks to servopump technology

• No need for a large footprint : more compact installation, smaller reservoir, fewer components

• High precision thanks to servopump control and closed-loop position feedback

• Full new CE marking

• PL e safety level thanks to Sitema clamping systems, light curtains, and integrated safety logic

Main press specifications

• Pressing force: 600 tonnes

• Mechanical overhaul: Complete refurbishment of the press frame + installation of new cylinders

• Precision: Closed-loop servopump control, positioning accuracy better than 0.1 mm

• Existing frame: Reused, fully requalified

• Closing speed: Adapted to production requirements

Hydraulic installation

• Operating pressure: Maximum 350 bar

• Servopump system: High-efficiency servopump technology by DV Hydraulics

• Hydraulic fluid: Hydraulic oil VG46

• Energy efficiency: 91% lower energy consumption (30 kW → 2.8 kW effective)

• Noise reduction: Significantly quieter operation thanks to variable-speed drive

Control and safety

Control: Siemens PLC platform with integrated closed-loop control

Functions:

• Precise position control

• Process monitoring before and after pressing

• Improved repeatability and consistent production quality

Safety (PL e):

• Sitema safety clamping systems

• Light curtains for safe operation

• Integrated safety logic

• Full new CE compliance

Efficient, safe, and future-ready

This refurbishment demonstrates that older presses can be transformed into modern, energy-efficient, and extremely precise machines with a minimal ecological footprint. Thanks to servopump technology, advanced Siemens control, and high-quality safety components, this 600-ton press once again delivers top-level performance — with one of the lowest energy consumptions in the industry.

Do you have a demanding refurbishment or modernisation project?

DV Hydraulics specialises in the design, construction, and refurbishment of hydraulic systems and presses. We combine power, precision, and energy efficiency in a tailor-made solution. Contact us — we will be happy to help.

Contact us!

This pre-stressed short-stroke press with a tailor-made hydraulic system was developed for extreme force, precision, and energy efficiency, with a focus on advanced control and maximum reliability. The press uses a servo pump system for highly efficient drive and is equipped with a Siemens S7-1518 PLC for precise and safe control.

Thanks to seamless integration into the complete production line, this press can produce a new sheet every 6 seconds, made possible by its continuous operation design.

Main Specifications of the Press:

• Pre-stressed frame: 16,000 tons

• Nominal pressing force: 12,800 tons

• Main cylinder: short stroke, rectangular: 800 x 800 x 15 mm

• Open/close cylinder: 300 x 260 x 150 mm

• Frame manufactured from forged components

• Total weight: 67 tons

• Fully in-house mechanical design and FEA simulation

• Precision-ground frame.

Main Specifications of the Hydraulic System:

• Nominal operating pressure: 2,000 bar

• Design pressure: 2,500 bar

• Pressure build-up speed: 1,000 bar/s or 6,400 tons/s

• Closed-loop speed control for fast opening and closing

• Precision force control with high-pressure measurement (0.1% accuracy, 10 kHz sampling)

• High-pressure medium: demineralized water

• Pilot system: hydraulic oil (250 bar)

• Energy-efficient drive system using servo pumps: 84% savings

  • Required power for conventional system: 90 kW

  • Actual consumption: 14.5 kW with Cos phi = 1

Control System Specifications:

• Proportional, custom-made high-pressure valves:

  • Operating pressure: 2,500 bar

  • Test pressure: 3,750 bar

  • Designed in-house

  • ATOS Axis controller as pilot valve.

• Siemens S7-1518 PLC and drives

This press combines extreme force, precision, and energy efficiency in one system.

Thanks to servo pump technology and a powerful Siemens PLC, this system is ideal for demanding industrial applications such as hydroforming.

At DV Hydraulics, we specialize in designing and building energy-efficient hydraulic presses that combine top performance with a minimal ecological footprint. Our innovative servo pumps deliver powerful, reliable, and energy-saving solutions – good for you and for the world of tomorrow. A servo pump system can be applied to many types of systems. Do you have an application where you want to save energy? Contact us!

• Variable hydraulic pump driven by an 11 kW electric motor (1450 rpm)

• Adjustable maximum operating pressure up to 70 bar

• Circulation pump for active oil cooling or heating via a plate heat exchanger

• Custom-built stainless steel 304L reservoirs – 200 liters, equipped with:

  • air breather filter

  • sight glass

  • combined level and temperature sensor

• Pressure and return filters with electrical contamination indicators

• Pressure relief valves with return to tank

• Compact, maintenance-friendly manifold blocks

All hydraulic piping was measured on site after positioning of the units and prefabricated to minimize installation time and downtime. All six installations were delivered with full technical documentation and successfully commissioned by our experienced service technicians, in line with GMP principles.

Do you have a project where GMP compliance, scalability, and compact hydraulic integration are essential?

Contact us to discover how DV Hydraulics can support your operation.

DV Hydraulics carried out a complete overhaul and recommissioning of a hydraulic test bench for the Belgian Defence.

This test bench is used for testing F-16 components, where reliability, accuracy, and maintainability are crucial.

During the inspection, it was found that the existing Parker PV Plus pump (PV092 – American type) showed significant wear.

To ensure operational reliability, the pump was replaced with a new Parker PV Plus PV092 in European configuration.

This choice guarantees identical performance, simplified maintenance, and better parts availability.

Work performed on the test bench:

• Complete inspection and functional check of the hydraulic installation.

• Replacement of the worn PV092 pump with a new European version.

• Replacement of all wear parts, including hydraulic hoses.

• Checking and adjustment of pressures, flow rates, and safety systems.

• Final functional testing of the entire test bench.

After completion of the work, the test bench was recommissioned and is fully operational for testing F-16 components.

This overhaul was carried out with a focus on reliability, ease of maintenance, and continuity of the installation.

Do you have a project that requires a reliable hydraulic partner? Contact us and discover how DV Hydraulics can support you.

Do you have a project that requires a reliable hydraulic partner, or would you like more information on ATOS or ISO cylinders? Contact us and discover how DV Hydraulics can support you.

At DV Hydraulics, we have fully overhauled and upgraded a dual Parker PVPlus pump (types PV270 and PV180, UDM version). These pumps are commonly used in heavy-duty hydraulic systems where reliability and precise control are essential.

Complete Overhaul to OEM Specifications

The overhaul included:

• Disassembly and inspection of all internal components.

• Replacement of wear parts such as bearings, seals, and control valves.

• Verification of hydrostatic bearings and compensator plates.

• Reassembly with genuine Parker parts.

• Testing on our test bench up to 350 bar, including:

  • Volumetric efficiency

  • Pressure control

  • Leakage check

After these steps, the pump once again meets original factory specifications, ensuring maximum reliability and service life.

Upgrade to CIP Displacement Sensors

In addition to the overhaul, we replaced the old measuring system with the new CIP displacement sensor system. This provides:

• Higher accuracy for electronic volume control.

• Full integration and replacement of the obsolete measuring system.

• Extended service life thanks to contactless measurement.

This upgrade is ideal for customers looking to extend the life of their existing pumps.

Why choose DV Hydraulics?

• Specialist in Parker PVPlus pumps and other hydraulic systems.

• In-house test facilities up to 350 bar.

• Fast turnaround and OEM quality.

• Custom upgrade options for sensors and control systems.

Do you have a Parker PVPlus pump that needs an overhaul or upgrade? Get in touch with our team via our contact page.