Universal Hydraulic Charging Rig, rated to 25 bar / 49 cc per stroke.

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.

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.

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.

Specifications

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.

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.

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.