Onsite Hydraulic Services for the Most Cost-Effective Downtime
Hydraulic systems in aircraft play a highly sensitive and vital role. From the deployment and retraction of landing gear to the control of flight surfaces , flaps, and
even braking systems—all rely on hydraulic power. This means that even the slightest leak or failure in these systems can immediately trigger serious warnings
and lead to aircraft grounding. In the past, many airlines would send aircraft to large hangars or even distant maintenance bases for any hydraulic issue . Today,
however, Onsite Hydraulic Services have become a widely adopted, agile,and economical solution that allows airlines to return their fleets to service with minimal
cost and downtime.
What Are Onsite Hydraulic Services?
Onsite Hydraulic Services encompass all maintenance, inspection, repair , and testing operations for aircraft hydraulic systems that are performed directly at the
aircraft’s parking location (ramp or local hangar). These services are carried out by deploying mobile technicians and specialized tools , eliminating the need to
transfer the aircraft to a main base.
These services may include:
Fixing leaks and replacing O-rings and packings
Charging and bleeding hydraulic systems
Functional testing of pumps, valves, and actuators
Inspecting and resolving issues related to filters and oil contamination indicators
Adjusting pressure and flow rate according to OEM technical specifications
Why Is This the Most Cost-Effective Approach?
Aircraft maintenance costs are not limited to parts or technician labor. The largest expense often comes from lost operational time. Each hour of downtime for a
passenger aircraft can result in thousands of dollars in direct and indirect losses.
Onsite Hydraulic Services allow for:
Repairs to be performed exactly where the aircraft is parked, eliminating the need for ferry flights or long-distance relocations
Immediate intervention by the technical team upon problem detection, minimizing resolution time
Reduced infrastructure investment, since MRO companies or airlines do not need costly permanent setups at every airport, lowering overall fleet maintenance costs
Requirements and Challenges of This Type of Service
While Onsite Hydraulic Repairs offer significant advantages , maintaining safety and quality standards is absolutely critical . Mobile teams must be fully trained and
equipped with portable testing and calibration tools (such as compact test stands or portable pressure check devices) . All consumables — filters , hoses , certified
hydraulic fluids, and O-rings— must comply with technical documentation (AMM or CMM) and be traceable by serial number . At the end of each service , a final
inspection must be completed, and a Release to Service issued according to regulations.
Example of Cost Savings in a Real Operation
For example, in a regional airline, a severe leak was detected in the nose gear hydraulic system. The initial plan was to transfer the aircraft to the main base, with
estimated direct costs (fuel, crew, parking, and preparation) of around $20,000. However, an Onsite Hydraulic Team was dispatched and resolved the issue within
8 hours by replacing a few packings and performing a full bleed of the system . The total cost was under $4,000 . The aircraft returned to its flight schedule the
same day.
The Future of Mobile Hydraulic Services
The advancement of portable test benches and new technologies for non-destructive testing of contamination or high – pressure line faults has rapidly expanded
this service model. Many MRO companies are developing mobile packages that fit into a container or even a specialized van, capable of deployment to any airport.
Conclusion
Onsite Hydraulic Services represent a modern and cost – efficient approach to managing aircraft fleet maintenance . By reducing downtime , eliminating transfer
expenses , and speeding up return – to – service processes , this model helps airlines maintain smoother , more economical , and highly reliable operations .
In the near future, this approach will become one of the core pillars of aircraft maintenance strategies.
Contact us for consultation and purchasing.