Modification of old Hydraulic Power Packs

Creative Power & Control specializes in the complete assessment, redesign and retrofitting of old hydraulic power packs using modern, standard pumps, valves and control components. Our in-house engineering team handles everything from initial diagnosis to final commissioning, delivering a power pack that meets today's production demands. We also carry out energy conservation by changing motor- pump combination & integration with PLC system

Why modify your existing power pack?

Hydraulic power packs have a long service life — but over time, pumps wear, internal leakages in valves increases, seals degrade and valves/ pumps become obsolete. Due to this cycle time increases lowering production. In many cases the steel reservoir, motor and frame are still structurally sound, making a full replacement unnecessary and expensive. A targeted modification restores the power pack to original — or improved — performance levels at a fraction of replacement cost, with minimum disruption to your production schedule. You can add additional hydraulic actuators as per changes in process.

Valve bank & manifold upgrade

Old, leaking or unavailable proprietary valves replaced with standard valves on new custom manifold blocks — reducing leak points and simplifying future maintenance.

Directional control valve replacement
Pressure relief, sequence and counterbalance valve re-setting or replacement
New custom manifold blocks with cartridge valves for compact circuits
Solenoid coil and electrical connector replacement

Pump replacement & upgrade

Worn or obsolete pumps replaced with modern equivalents — same bell housing mounting, superior performance and readily available spares.

Gear pump replacement with same or higher displacement
Fixed-displacement to variable-displacement conversion for energy saving
Single to tandem pump configuration for dual-pressure circuits
Bell housing re-alignment and flexible coupling replacement

Signs your power pack needs modification

If your power pack displays any of the following symptoms, a modification assessment is recommended.

System overheating — oil temperature exceeding 60°C under normal load
Slow cycle times — reduced flow rate or inability to hold pressure
Excessive pump noise or cavitation sounds during operation
Frequent external oil leaks from valve bodies or pipe joints

What we modify

Each modification is scoped to the specific condition of your power pack. We replace only what is necessary — preserving sound existing components to minimize cost and downtime.

Pressure relief valve chattering or inability to set stable pressure
Solenoid valve coil burnouts
Spare parts for existing components no longer available
Increased energy consumption with no change in production output

Common warning signs

Reservoir & filtration overhaul

Tank cleaning, filtration system upgrade and oil cooling improvement to ensure clean oil, stable operating temperature and extended component life.

New suction strainer, return line filter and filler breather
Oil level gauge, float switch and temperature gauge replacement
Offline Oil cooler addition or upgrade — air blast or water cooled

Electrical & control system update

Modernization of the electrical panel, pressure switches and pressure transmitters to improve reliability and ease of troubleshooting.

New control panel with updated wiring and labelling
Pressure switch and transducer replacement
Motor starter and overload relay upgrade
Addition of hour meter, fault indicators and digital pressure display

Industries & equipment we service

We have successfully modified hydraulic power packs across a wide range of industrial sectors.

Modification of old Hydraulic Power Packs

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