Universal Hydraulic Charging Rig

Universal Hydraulic Charging Rigs for Aviation and Industrial Applications Efficient maintenance of aircraft hydraulic systems relies on advanced universal hydraulic charging rigs and hydraulic charging rigs. Designed for both field and hangar operations, aircraft hydraulic chargers and portable hydraulic chargers provide precise, safe, and leak-free fluid replenishment. Manual hydraulic pump rigs and precision hydraulic pump rigs offer reliable control for topping up hydraulic systems while ensuring compliance with standards like ISO 4406 hydraulic cleanliness. Modern rigs, such as hydraulic fluid replenishment rigs and high-pressure hydraulic chargers, often feature stainless steel construction and 3 μm filtration charging rigs to maintain fluid purity. Specialized units, including aerospace ground support chargers, MiG hydraulic fill rigs, and Su-30 hydraulic charging units, are optimized for demanding military aviation operations. Trolley-mounted solutions, emergency hydraulic refill units, and field hydraulic charging stations enhance mobility and rapid response. These hydraulic system top-up devices ensure safe, efficient, and leak-free hydraulic charging, making them indispensable in aviation and industrial hydraulic maintenance.

About

The Universal Hydraulic Charging Rig is a rugged, portable system designed for precise,contamination-free replenishment of hydraulic circuits in both military and civil aerospace applications. Its 25 L stainless-steel reservoir and high-leverage manual piston pump deliver up to 25 bar at 49 cc per stroke, while an integrated 3 μm filtration system ensures oil cleanliness to ISO 4406 standards. Equipped with quick-change adaptors compatible with Su- and MiG-series fittings, a visual pressure gauge, over-pressure relief valve, and a m reinforced hose on an ergonomic trolley, the rig enables safe, efficient top-ups during frontline servicing, depot maintenance, or emergency recovery. Routine maintenance protocols—including scheduled filter replacements, fluid changes, and pressure tests—keep the unit mission-ready, making the A-1760 an essential tool for ensuring hydraulic system reliability and minimizing aircraft downtime.

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Technical Details

Specifications

            
  
    
      Parameter
      Details
    
  
  
    
      Fluid Type
      Mineral hydraulic oil OM-15 (MIL-PRF-5606)
    
    
      Max. Pressure
      25 kg/cm² (≈25 bar)
    
    
      Flow per Stroke
      49 cc
    
    
      Reservoir Capacity
      25 L
    
    
      Filter Rating
      3 µm (Duplex/simplex β ≥ 200)
    
    
      Hose
      5 m length, 30 mm OD; 1,000 bar burst
    
    
      Gauge
      0–120 kg/cm², Ø 100 mm, glycerine-filled
    
    
      Materials
      SS-304 tank & fittings, plated steel pump
    
    
      Operating Temp.
      –10 °C to +50 °C
    
    
      Mobility
      4 × polyurethane swivel castors, 2 with brakes
    
    
      Overall Weight
      ~30 kg (packed)

Parameter	Details
Fluid Type	Mineral hydraulic oil OM-15 (MIL-PRF-5606)
Max. Pressure	25 kg/cm² (≈25 bar)
Flow per Stroke	49 cc
Reservoir Capacity	25 L
Filter Rating	3 µm (Duplex/simplex β ≥ 200)
Hose	5 m length, 30 mm OD; 1,000 bar burst
Gauge	0–120 kg/cm², Ø 100 mm, glycerine-filled
Materials	SS-304 tank & fittings, plated steel pump
Operating Temp.	–10 °C to +50 °C
Mobility	4 × polyurethane swivel castors, 2 with brakes
Overall Weight	~30 kg (packed)

Applications

- Frontline Aircraft Servicing: Rapid top-up of hydraulic reservoirs after high-altitude sorties or ground tests, ensuring immediate return-to-service.
- Depot and Field Maintenance: Ideal for hangar-level or expeditionary maintenance, where bulk hydraulic carts are impractical.
- Civil & Military Ground Support: Compatible with a wide range of hydraulic systems beyond fighters—helicopters, transport aircraft, and even heavy-lift drones.
- Emergency Recovery: Provides on-spot hydraulic pressure restoration to enable safe taxi or ground repositioning in case of leaks.

FAQ

Details

1. Introduction
The Universal Hydraulic Charging Rig is engineered to deliver precise, contamination-free replenishment of hydraulic circuits in frontline fighter aircraft (e.g., Su-30, MiG-29) and other aerospace platforms. Its robust stainless-steel reservoir, combined with a manually actuated piston pump, ensures dependable operation even in austere or remote airbase environments. The rig’s integrated 3 μm filtration system removes particulate down to ISO 4406 cleanliness levels, protecting valves, actuators, and servo-controls from wear and failure. The compact trolley design—with lockable polyurethane wheels—facilitates safe handling and rapid deployment, reducing ground-support turnaround times.

2. Applications
- Frontline Aircraft Servicing: Rapid top-up of hydraulic reservoirs after high-altitude sorties or ground tests, ensuring immediate return-to-service.
- Depot and Field Maintenance: Ideal for hangar-level or expeditionary maintenance, where bulk hydraulic carts are impractical.
- Civil & Military Ground Support: Compatible with a wide range of hydraulic systems beyond fighters—helicopters, transport aircraft, and even heavy-lift drones.
- Emergency Recovery: Provides on-spot hydraulic pressure restoration to enable safe taxi or ground repositioning in case of leaks.

3. Key Features
- Precision Manual Pump: High-leverage hand actuator delivers up to 100 kg/cm2 (≈98 bar) at a calibrated 49 cc per stroke.
- Corrosion-Resistant Reservoir: 25 L SS-304 tank, pressure-tested and polished internally to reduce particle adhesion.
- Ultra-Fine Filtration: Duplex β 200 filters (3 μm rating) capture contaminants before pump intake.
- Universal Adaptability: Quick-change adaptors cover MIL-STD hydraulic fittings for Su-series and MiG-series aircraft.
- Integrated Safety Features: Over-pressure relief valve pre-set at 110 bar; visual pressure gauge (0–120 kg/cm2).
- Ergonomic & Mobile: 5 m, 30 mm-OD reinforced hose with quick-disconnect coupling; two-tier trolley shelf and hose reel.

4. Specifications

Parameter
Details

Fluid Type
Mineral hydraulic oil OM-15 (MIL-PRF-5606)

Max. Pressure
25 kg/cm² (≈25 bar)

Flow per Stroke
49 cc

Reservoir Capacity
25 L

Filter Rating
3 µm (Duplex/simplex β ≥ 200)

Hose
5 m length, 30 mm OD; 1,000 bar burst

Gauge
0–120 kg/cm², Ø 100 mm, glycerine-filled

Materials
SS-304 tank & fittings, plated steel pump

Operating Temp.
–10 °C to +50 °C

Mobility
4 × polyurethane swivel castors, 2 with brakes

Overall Weight
~30 kg (packed)

5. Operating Procedure
- Setup & Inspection: Place rig on a level surface; lock trolley brakes. Check oil level and inspect filter housing.
- Connection: Attach correct adaptor; hand-tighten coupling onto aircraft port. Route hose to avoid kinks.
- Priming & Pumping: Open relief valve fully to prime; pump until oil is bubble-free. Close valve to desired pressure.
- Monitoring: Observe gauge; do not exceed 25 bar. If pressure stalls, allow system stabilization.
- Shutdown & Disconnection: Loosen relief valve to depressurize; pump to bleed residual pressure. Disconnect and cap.
- Post-Use Check: Wipe spilt oil; inspect fittings for leaks; store in a covered, climate- controlled area.

6. Maintenance
- Daily: Wipe down external surfaces; check for leaks or damage on hoses and couplings.
- Monthly: Drain and clean reservoir; inspect interior for varnish or sludge; refill with fresh OM-15 oil.
- Quarterly: Replace filter elements; verify relief valve and gauge accuracy.
- Annually: Pressure-test tank and hose assembly at 1.5 × max operating pressure; service or replace seals.
- Record Keeping: Maintain a log of fluid changes, filter swaps, and pressure tests per MIL- H-5606 protocols.

7. Conclusion
With its combination of fine filtration, precise manual control, and modular adaptability, the A-1760 Universal Hydraulic Charging Rig is an indispensable asset for military and civil aerospace maintenance teams. By minimizing contamination risk and maximizing portability, it ensures hydraulic systems are reliably topped up, kept clean, and ready for mission-critical operations.