Details

About the Machine
The Test Rig for Hydraulic Fluid is engineered to evaluate the anti-wear properties and oxidation (aging) behavior of hydraulic fluids under strictly controlled, reproducible conditions. It employs two industry-standard test pumps as the load elements:
- Vane Pump (Vickers 35VQ25A-11*20) for ASTM D6973-2014 testing
- Bent-Axis Axial Piston Pump (A2F10) for JCMAS P 045 testing
By analyzing mass loss of wear inserts (cam ring and vanes) and monitoring fluid condition post-test, the rig quantifies how well a fluid resists wear and oxidation. A rotary vane pump generates the required test pressure, and a pressure-relief valve on the bent-axis circuit
creates high-temperature stresses in the presence of air and a copper catalyst—accelerating aging in a realistic hydraulic component. All design and safety features comply with the European Machinery Directive 2006/42/EC (or equivalent Indian standards).

Technical Specifications

  

    

      
Parameter
      
Value
    
  
  

    
Operating Design Pressure
207 bar
    
Maximum System Pressure
250 bar
    
Max Flow (Main Pump)
~170 L/min
    
Power Supply
3-phase, 415 V ±10%, 50 Hz; 24 V DC control
    
Input Power
110 kW (VFD-controlled)
    
Fluid Cleanliness
NAS 1638 Class 6 or better
    
Fluid Viscosity
ISO VG 32, 46, 68
    
Duty Cycle
Intermittent
  


Test Parameters (ASTM D6973-2014):

  

    

      
Test Parameter
      
Value
    
  
  

    
Pump Speed
2,400 RPM ± 20
    
Outlet Pressure
6.9, 13.8, 20.7 MPa ± 0.2 MPa
    
Oil Temperature
52 °C, 79 °C, 95 °C ± 3 °C
    
Run Time
30 min (at 6.9 & 13.8 MPa); 49 min (at 20.7 MPa)
    
Minimum Flow
132 L/min
  


2. JCMAS P 045 Test Rig

  

    

      
Parameter
      
Value
    
  
  

    
Operating Design Pressure
350 bar
    
Maximum System Pressure
420 bar
    
Pump Flow
10.3 cc/rev
    
Power Supply
3-phase, 415 V ±10%, 50 Hz; 24 V DC control
    
Input Power
45 kW (VFD-controlled)
    
Fluid Cleanliness
NAS 1638 Class 6 or better
    
Viscosity Grades
ISO VG 32, 46, 68
    
Duty Cycle
Intermittent
  


Test Parameters (JCMAS P 045):

  

    

      
Test Parameter
      
Value
    
  
  

    
Pump Speed
2,600 RPM ± 1
    
Outlet Pressure
35 MPa ± 0.1 MPa
    
Suction Temp
90 °C ± 1 °C
    
Air Dosing
0.1 L/h @ 20 °C
    
Water Dosing
0–100 mL/h
    
Catalyst
0.3 m² copper sheet + rubber seals
    
Operating Time
500 hours
    
Sample Collection
6 samples up to 300 mL each
  


Key Features of the Machine
• Highly Repeatable & Reproducible: Meets or exceeds ASTM D6973-14 & JCMAS P 045 tolerances.
• Fully Automatic Sample Taking: Programmable during tests without operator intervention.
• Automatic Temperature Control: Precisely maintains oil and ambient temperatures per test protocols.
• Flexible Test Methods: Easily adapts to future standard revisions or custom industry requirements.
• Dual Aging Modes: Air and water dosing in suction line for accelerated oxidation testing.
• High-Capacity Power Packs: ASTM circuit up to 300 L/min @ 207 bar; JCMAS circuit upto 70 L/min @ 350 bar.
• High-Resolution Data Logging: Captures test data every 0.1 sec for detailed post-analysis.

Application – Expanded Use Cases
1. Lubricant & Fluid Manufacturers:
Product Development: Benchmark new formulations for wear resistance and oxidation stability against industry standards, shortening time-to-market.
Quality Control: Run routine batch-release tests to ensure each production lot meets strict NAS cleanliness and viscosity specifications before shipping.

2. Automotive & Heavy-Equipment OEMs:
Supplier Qualification: Validate that incoming hydraulic fluids from third-party suppliers comply with contractually mandated performance criteria (ASTM D6973-14 and JCMAS P045).
In-House R&D: Characterize fluid behavior under chassis, transmission or hydraulic-steering load profiles to optimize system efficiency and durability.

3. Aerospace & Defense Laboratories:
Mission-Critical Fluids: Test specialty non-petroleum and fire-resistant hydraulic fluids under accelerated aging to confirm performance in extreme temperatures and high-pressure pulses.
Regulatory Certification: Generate data packages for civil and military certifying bodies, demonstrating compliance with ISO, MIL-SPEC and OEM fluid standards.

4. Test & Certification Houses:
Third-Party Testing: Offer independent, traceable test reports to equipment manufacturers, insurance underwriters and regulatory agencies.
Custom Protocols: Implement user-defined test cycles (varying load, temperature, dosing regimes) for niche applications like marine hydraulics or renewable-energy drives.

5. Academic & Research Institutions:
Fundamental Research: Investigate tribological mechanisms of wear inserts (vanes, cam rings) and study catalytic oxidation processes in fluid media.
Graduate Projects: Provide hands-on experience with automated test benches, data acquisition and statistical analysis of wear-and-aging phenomena.

6. Maintenance & Service Facilities:
Field Fluid Assessment: Simulate in-service stress conditions to advise on fluid change intervals and contamination control strategies in industrial hydraulic systems.
Failure Analysis: Reproduce real-world operating scenarios to root-cause hydraulic-fluid–related equipment failures and recommend corrective actions.

Conclusion
The A3987 Test Rig for Hydraulic Fluid combines precision, automation and standards-compliance to deliver high-fidelity insights into fluid wear and aging behavior. Its dual-pump architecture, automatic sampling and tight environmental control make it equally adept at routine quality checks, R&D exploration and third-party certification. By generating detailed, reproducible datasets captured every 0.1 seconds, this test bench empowers engineers, scientists and quality managers to:
- Optimize fluid formulations for maximum component life
- Validate supplier materials against global test protocols
- Accelerate product development and reduce non-compliance risk
- Deepen understanding of tribological and oxidative mechanisms
Incorporating the A3987 into your test lab not only ensures adherence to ASTM D6973-14 and JCMAS P 045, but also fosters continuous innovation in hydraulic-fluid technology, driving performance gains and cost savings across your operations.