Hydraulic Hose/Tube Proof Test Stand, rated to 690 bar (10,000 psi).

Introduction

The Hydraulic Hose/Tube Proof Test Stand is engineered for rigorous static pressure testing of hydraulic hoses and tubes in industrial and aerospace maintenance environments. Its dual-chamber, floor-mounted enclosure houses both a high-capacity electric gear pump and an air-driven Haskel pump, delivering up to 690 bar (10,000 psi) of hydraulic pressure. All hydraulic circuits are routed through multistage filtration and a plate-type heat exchanger to ensure fluid cleanliness and thermal stability during extended test cycles. An integrated safety hood with polycarbonate viewing windows and an interlocked limit switch offers full operator protection. The unit's modular steel cabinet, finished in corrosion-resistant powder coat, sits on adjustable vibration-dampening feet for stability on uneven floors. Comprehensive instrumentation — a digital pressure transmitter with 4-20 mA output, analog gauges, a programmable timer, and an emergency-stop — ensures precise, repeatable testing to meet stringent quality and regulatory requirements.

Key features

Dual-source pressurization

• Electric gear pump (Rexroth AZPW21004): 4 cc displacement, 5 L/min flow; driven by a 3 HP, 1,420 RPM, three-phase motor for rapid, stable pressurization up to 800 bar.
• Air-driven Haskel pump (MS 188): delivers up to 1,500 psi for fine manual control or back-up operation; actuated via a simple lever handle.

Advanced fluid conditioning

• Triple-stage filtration: inline elements rated at 10 µm, 6 µm, and 3 µm remove particulate contamination before high-pressure delivery.
• Plate-type heat exchanger: maintains oil temperature within 20-40°C, protecting seals and ensuring consistent viscosity.

Precision instrumentation

• Digital pressure transmitter: 0-1,000 bar range, 4-20 mA loop output to external data acquisition or PLC.
• Analog gauges: Bourdon gauge (0-800 bar) and pneumatic gauge (0-16 bar).
• Timer and selector switch: front-panel timer allows test durations from 1 s to 99 h 59 m, with manual or automatic start/stop modes.

Safety & ergonomics

• Enclosed test chamber: double-walled steel safety hood with two tempered-glass windows (250 × 250 mm each), rated to withstand full system pressure.
• Limit-switch interlock: automatically vents pressure if the hood is opened mid-cycle.
• Emergency-stop mushroom button: immediately de-energizes pumps and opens the main relief valve.

Oil management

• Sliding oil-collecting tray: positioned directly beneath the chamber for rapid removal of drain oil; tray capacity of 5 L.
• Permanent drip tray: catches overflow or accidental drips, routed to a 2 L sump for easy disposal.

Robust construction

• Cabinet material: 2 mm mild-steel enclosure with RAL 7032 powder coat; corrosion-resistant and easy to clean.
• Viewing windows: 6 mm polycarbonate sheets, UV stabilized and scratch resistant.
• Mounting: four adjustable, anti-vibration feet accommodate floor irregularities up to ±10 mm.

Bill of materials (highlights)

Installation & commissioning

• 1. Site preparation: level concrete floor rated ≥ 1,000 kg; ambient 0-45°C, < 90% RH. Clearance of 300 mm all around; no direct sun.
• 2. Power connections: 415 VAC three-phase (pump); 220 VAC single-phase (controls). Cable ≥ 4 mm² copper; earth-ground < 1 Ω.
• 3. Hydraulic hookup: fill with OM 15 oil to the high mark; bleed via the pump inlet screw.
• 4. Functional checks: verify motor rotation (CW from rear); inspect filters, hoses, and interlocks.
• 5. Initial test run: dry-run pump 5 min, monitoring current < 80% rated. Pressurize to 100 bar, hold 1 min, and inspect for leaks. Execute three 690 bar cycles (2 min hold); pressure drift < ±5 bar.

Maintenance & troubleshooting

• Daily: inspect oil level, gauge zero, and E-stop function.
• Weekly: clean and test the hood switch; filter Δp < 1 bar.
• Monthly: drain tank, replace the 10 µm filter if Δp > 0.5 bar, and torque bolts.
• Quarterly: clean the heat exchanger, calibrate the transmitter, and run a leak-down test at 500 bar (Δp < 10 bar).
• Annual: overhaul pumps, replace filters, and burst-test the chamber at 1.25× working pressure.

Conclusion

The Hydraulic Hose/Tube Proof Test Stand represents a comprehensive, turnkey solution for high-pressure proof testing in demanding industrial and aerospace environments. By combining dual-source pressurization, advanced fluid conditioning, precision instrumentation, and robust safety features within a corrosion-resistant, ergonomically designed cabinet, it delivers repeatable, accurate results while ensuring operator protection and ease of maintenance. Whether validating hydraulic assemblies for aircraft, heavy equipment, or R&D applications, this hydraulic hose test stand stands out for its reliability, versatility, and compliance with international safety standards. Optional PLC integration, extended-capacity chambers, and acoustic enclosures offer further customization to fit unique facility workflows and testing protocols.