Aircraft Hydraulic Test Rigs

Hydraulic systems are the muscles of an aircraft. Landing gear, flight controls, cargo doors, thrust reversers, brakes all rely on stable hydraulic power. If those systems are not tested and verified properly on the ground, every flight is taking an unnecessary risk.

This is exactly where hydraulic test rigs also called hydraulic test stands or "mules" become critical Ground Support Equipment. They allow airlines, MROs, and defense operators to simulate real aircraft hydraulic conditions on the ground, diagnose problems, flush contamination, and certify components before the aircraft ever leaves the hangar. AVA AERO

For AVA AERO and our customers in the Middle East, choosing the right hydraulic test rig is not only a technical decision, it is a strategic one that affects safety, dispatch reliability, and total maintenance cost.

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What A Hydraulic Test Rig Actually Does

A hydraulic test rig is a self contained unit with pumps, reservoirs, filters, valves, gauges, and control panels that connect to the aircraft or to individual components. It can:

• Generate and control hydraulic pressure and flow, typically up to 3000 to 6000 psi depending on the model.

• Power aircraft systems externally so you can test landing gear, flaps, flight controls, brakes, and actuators without running the engines.

• Flush and purify hydraulic fluid to remove moisture, dissolved gases, and particles down to a few microns, bringing cleanliness to demanding standards.V-22 Ground Support Equipment

• Simulate different operating conditions to troubleshoot leaks, abnormal pressures, and sluggish actuators before they become in flight problems.

In short, the test rig is the "ground-based hydraulic heart" that keeps aircraft systems healthy and predictable.

Variations - Pressure, Flow, And Configuration

Not all aircraft use the same hydraulic architecture, and not all rigs are designed for the same job. Hydraulics International Inc. (HII) offers a wide portfolio of portable and towable hydraulic test stands that are tailored to different aircraft types and maintenance philosophies.

Key variations include:

Pressure and flow

• Narrow body aircraft test stands typically operate up to 5000 psi, with flows in the range of roughly 6 to 15 gpm depending on configuration.

• Heavy helicopter and tiltrotor platforms such as the V 22 can require up to 6000 psi and flows up to 55 gpm at lower pressures.

Drive type

• Electric motor driven units are ideal for hangar operations with stable power supply, quieter operation, and lower emissions.

• Diesel engine driven units are preferred on remote ramps, military airfields, or where electrical infrastructure is limited. Many HII systems are available in both configurations.

  
  

Mobility and format

• Compact portable stands for narrow body fleets and line maintenance.

• Towable dual output diesel test stands for large military bases or multi bay hangars, combining two independent hydraulic systems in one unit.

Platform specific variants HII has developed dedicated hydraulic test stands for platforms such as the B737, V 22 Osprey, F 16, and F 35, each tuned to the aircraft hydraulic requirements and interfaces.

READ MORE:

https://www.avaet.com/hydraulics-lubrication-1/large-body-portable-hydraulic-test-stand

High Quality Hydraulic Test Rigs Vs Cheap Alternatives

At first glance, low cost hydraulic test rigs can look "good enough". They may even claim similar pressure and flow numbers on paper. But in real operations, the gap between a high quality unit and a cheap one shows up quickly in four main areas.

1. Filtration and contamination control

In aviation hydraulics, contamination is the silent killer. High quality rigs from HII use multi stage filtration down to 3 to 5 microns, with differential pressure indicators and often integrated purification systems that remove moisture, dissolved gases, and particles to cleanliness levels equal to or better than NAS 1638 class 3.

Cheaper rigs may:

• Use only coarse filtration

• Bypass filters when clogged

• Offer no clear indication of contamination level

The result is that instead of cleaning the aircraft system, you might actually be introducing new contamination into it.

2. Pressure stability and instrumentation

High quality hydraulic test stands deliver:

• Stable, repeatable output pressure across the full flow range

• Precise control valves and calibrated gauges

• Reliable flowmeters and temperature monitoring

This is essential for accurate troubleshooting and for meeting OEM maintenance procedures. Low quality units often have drifting gauges, unstable pressure under load, and poor repeatability which makes diagnostics unreliable and wastes technician time.

3. Build quality and safety

Aviation grade test stands are designed for continuous operation in harsh environments, with properly rated hoses, fittings, pressure relief, and safety interlocks. HII systems are qualified to rigorous military and environmental standards, supporting both commercial and defense operators worldwide.

Cheap units may cut corners on:

• Hose and fitting quality

• Reservoir design

• Structural strength of the cart or frame

At 3000 to 6000 psi, those compromises are not only expensive, they can be dangerous.

4. Lifecycle cost

Operators often discover that low cost test rigs:

• Require frequent repair and downtime

• Lack proper documentation and OEM support

• Cannot be upgraded or reconfigured for new aircraft types

A high quality HII stand has a higher initial cost, but delivers a much lower cost per operating hour when you factor in reliability, safety, reduced AOG risk, and long term service support.

Portable Helicopter Hydraulic test stand https://www.avaet.com/hydraulics-lubrication-1/general-aviation-portable-hydraulic-test-stand

Examples Of HII Portable Hydraulic Test Stands

Below is an overview of selected Hydraulics International hydraulic test stand part numbers used on commercial and military platforms worldwide. These illustrate the breadth of the HII portfolio from narrow body commercial fleets to advanced fighters and tiltrotors.

Note: Technical details such as pressure, flow, and exact configuration are summarized from open source descriptions. For detailed data sheets and engineering support, AVA AERO can provide official HII documentation on request.

CHECK THE HYDRAULICS PRODUCTS

HII Part Number	Typical Application / Platform	Drive Type	Notes
93085-100	Portable hydraulic test stand for narrow body commercial aircraft (Airbus A318/A319/A320, Boeing 737/757 variants)	Electric or diesel options	Compact portable stand optimized for line and hangar maintenance, up to 5000 psi with 6 to 15 gpm flow range depending on configuration.
93086-100	Portable test stand variant for similar narrow body fleets	Electric or diesel options	Alternative configuration within same family, tailored for specific operator or OEM requirements.
93087-100	Portable test stand for A320 and 737 family supportAVA AERO	Electric or diesel options	Configured for different flow or redundancy requirements within the same aircraft group.
93176-100	B737 portable hydraulic test stand / aerospace hydraulic test stand	Electric motor driven (also integrated with diesel powered variants 040489-100SS)	Platform specific solution for B737 and related applications, used by airlines and MROs as a dedicated rig for that fleet.
070515-100 (MJ-2A)	Portable hydraulic test stand for F 16	Diesel engine driven	Air Force portable hydraulic test stand used on F 16 aircraft, configured for fast deployment and robust field operations.
081013-100	Hydraulic test stand for F 35 or JSF (JSF weapon loaders suite)	Electric motor driven	Integrated as part of F 35 ground support equipment, aligned with JSF program requirements.
081218-100	Portable hydraulic test stand for F 35 or JSF	Diesel engine driven	Expeditionary configuration for F 35 operations where electrical infrastructure is limited.
98612-100	V 22 portable hydraulic test stand / power supplyV-22 Ground Support Equipment (GSE)	Electric motor driven	Supports V 22 Osprey hydraulics with flow up to 55 gpm at 3000 psi, 32 gpm at 5000 psi, and 20 gpm at 6000 psi, with integrated purification.
000850-100 to 111025-100 series	V 22 portable hydraulic test stand variantsV-22 Ground Support Equipment (GSE)	Diesel engine driven	Series of diesel driven units for V 22, with engine configuration changes from Tier 2 to Tier 3, covering different deployment and emissions requirements.
202527-100	Towable dual output diesel hydraulic test stand (US Air Force contract)	Diesel engine driven	Dual output stand providing two independent hydraulic systems in a towable configuration, ideal for large bases and multi bay hangars.

This list is not exhaustive. HII maintains a very wide catalog of hydraulic test rigs, including universal benches, component test stands, and customized units for specific airframes and defense applications.

AVA AERO - Your HII Hydraulic Test Rig Partner In The Middle East

AVA AERO is the official representative and supplier of Hydraulics International Inc. in the Middle East, supporting airlines, MROs, and defense operators across the region.

What we provide:

• Supply of HII hydraulic test rigs, from portable stands for narrow body fleets to platform specific solutions for F 16, F 35, V 22, and B737.

• Technical support in selecting the correct part number and configuration for your fleet, maintenance concept, and local infrastructure.

• Coordination with HII for documentation, training, and after sales support.

• Integration with your broader Ground Support Equipment strategy, including nitrogen carts, cabin leakage testers, and other GSE already offered by AVA AERO.

If you are planning a new hangar, upgrading an MRO facility, or standardizing GSE across your fleet in the GCC or wider Middle East, AVA AERO can help you build a robust hydraulic test rig strategy based on proven HII equipment.

Pricing and inquiries