New Generation 5000 PSI Hydraulic Test Stand

The New Generation 5000 PSI Hydraulic Test Stand (Part Number: 101198-100) is an advanced, electric motor-driven hydraulic testing system engineered by Hydraulics International, Inc. (HII). This high-performance unit is specifically designed for comprehensive servicing, testing, and troubleshooting of hydraulic systems on modern commercial and military aircraft. It delivers precise and reliable hydraulic power, achieving operational pressures of up to 5000 PSI, making it ideal for supporting advanced aircraft maintenance requirements.

Technical Details:

This Hydraulic Test Stand features two independent hydraulic systems, each driven by a robust electric motor, providing redundancy, efficiency, and flexibility. Each system is capable of delivering flow rates up to 32 gallons per minute (GPM) at pressures reaching 5000 PSI, or higher flow rates at reduced pressures (up to 53 GPM at 3000 PSI per system). When both hydraulic systems are combined, the total flow rate capability increases significantly, allowing up to 106 GPM at 3000 PSI, or 64 GPM at the maximum operating pressure of 5000 PSI.

An integral feature of this test stand is its advanced Hydraulic Purification System (HPS), ensuring optimal fluid cleanliness. The purification process effectively removes contaminants, particulates, air bubbles, gases, moisture, and chlorinated solvents from the hydraulic fluid, meeting NAS 1638 Class 3 cleanliness standards or better. This capability is essential for maintaining the longevity and operational integrity of aircraft hydraulic components.

The test stand is driven by a robust electric motor, which significantly reduces emissions, noise, and maintenance downtime compared to traditional diesel-driven systems. Its electric-driven operation is particularly advantageous within enclosed facilities or environmentally regulated areas.

To enhance operational ease and precision, the test stand includes an advanced Human-Machine Interface (HMI). This interface provides real-time monitoring of critical parameters such as hydraulic pressures, flow rates, fluid temperatures, and diagnostic data, improving operational accuracy and efficiency. Operators can quickly identify performance issues, streamline troubleshooting, and reduce turnaround times during maintenance activities.

Additionally, the equipment is designed with a highly efficient filtration and purification system that continuously maintains fluid cleanliness by removing contaminants, water, air, and particulates, thereby consistently achieving fluid cleanliness standards of NAS 1638 Class 3 or better.

The rugged construction of the test stand ensures reliable performance under various environmental conditions. It is built to withstand extreme temperature ranges (-40ºF to +125ºF), variable humidity levels (0% to 100%), and operation at altitudes ranging from sea level up to 6000 feet, making it suitable for diverse operational scenarios.

Applications:

• Routine Aircraft Hydraulic Maintenance: Ideal for the maintenance of advanced aircraft hydraulic systems on platforms such as F-16, F-15, F-18, F-35, FA-50, KF-21, and other modern aircraft, ensuring readiness and reliability.

• Component Testing and Certification: Suitable for rigorous testing of hydraulic components including pumps, motors, actuators, and valves. It helps validate performance to OEM and regulatory standards.

• Manufacturing & Assembly Operations: Essential equipment for aircraft manufacturers, providing hydraulic power during assembly and quality assurance phases, ensuring each component and system meets stringent industry requirements.

• Hydraulic Fluid Purification: Utilized to cleanse and condition hydraulic fluid, prolonging component lifespan and ensuring safe, reliable aircraft operation.

Technical Specifications Table: