Analog Hydraulic Test Kits for Pressure Measurements

Frequently Asked Questions About Analog Hydraulic Diagnostic Tools

Analog hydraulic test kits combine rugged dial gauges with measuring hoses, test connections, and adapters to form a portable system for hydraulic pressure measurements. They are particularly well-suited for workshops and service technicians who want to check system pressures directly on vehicles, machines, or stationary hydraulic systems and prefer to use a classic analog pressure gauge.

Leitenberger Automotive Test Equipment offers analog hydraulic test kits with one, two, or three pressure gauges. Depending on the model, measurement ranges of 0–25, 0–100, and 0–400 bar are available. The kits include matching test hoses as well as various test and reducer fittings for professional workshop and service use.

• What is an analog hydraulic test kit?

  An analog hydraulic test kit is a fully assembled pressure measurement system for hydraulic systems.

  Depending on the model, the kit contains:

  • one or more analog pressure gauges
  • measuring hoses
  • pressure gauge connections
  • test connections
  • reducers
  • connectors
  • a custom-designed carrying case

  This provides all the essential components needed for various hydraulic pressure measurements in a single kit.

• What analog hydraulic test kits does Leitenberger offer?

  Currently, three HPK models are available:

  HPK 10_LR

  • 1 analog pressure gauge
  • Measuring range 0–400 bar

  HPK 20_LR

  • 2 analog pressure gauges
  • Measuring ranges: 0–100 and 0–400 bar

  HPK 30_LR

  • 3 analog pressure gauges
  • Measuring ranges: 0–25, 0–100, and 0–400 bar

  This allows the test kit to be selected based on the required pressure range and the vehicle or machinery fleet.

• What is the HPK 10_LR?

  The HPK 10_LR is the compact version with an analog pressure gauge.

  The measurement range is 0–400 bar.

  The scope of delivery includes, among other items:

  • Pressure gauge, nominal size 63
  • 2-meter measuring hose
  • Direct pressure gauge connection G1/4
  • Test connection G1/4
  • Test connection M10 × 1
  • Pressure reducer
  • Hose connector
  • Carrying case

  The case is particularly suitable for workshops that primarily perform hydraulic pressure measurements within a comparable pressure range.

• What is the HPK 20_LR?

  The HPK 20_LR includes two analog pressure gauges with different measurement ranges:

  • 0–100 bar
  • 0–400 bar

  This allows you to select the pressure gauge best suited for the specific measurement task.

  In addition, the case contains two 2-meter measurement hoses as well as various test and reducer fittings.

• What is the HPK 30_LR?

  The HPK 30_LR is the most comprehensive standard model in the analog HPK series.

  The case contains three pressure gauges with ranges of:

  • 0–25 bar
  • 0–100 bar
  • 0–400 bar

  This allows both comparatively low hydraulic pressures and the typically higher pressures found in working hydraulic systems to be covered by a single test kit.

• Why does the HPK 30_LR include a 25-bar pressure gauge?

  Not every hydraulic measuring point operates at several hundred bar.
  
  At lower system pressures, a smaller measuring range is often better suited to the actual measurement task.
  
  The 0–25-bar pressure gauge therefore complements the 100- and 400-bar models and extends the test kit’s range of application to lower pressures.

• Why does the HPK 20_LR include a 100-bar and a 400-bar pressure gauge?

  The two measurement ranges allow for better adaptation to different hydraulic systems.
  
  The 100-bar pressure gauge can be used for lower pressures.
  
  The 400-bar pressure gauge is available for higher system pressures.
  
  This means that not every measurement has to be taken using the same wide measurement range.

• Which analog test kit should I choose?

  The selection depends in particular on:

  • the expected hydraulic pressures
  • the machines that are regularly tested
  • the number of measurement ranges required
  • the available test connections
  • the desired flexibility for mobile service

  If pressures up to 400 bar are primarily being monitored, the HPK 10_LR may be sufficient.

  For a wider range of pressure ranges, the HPK 20_LR and, in particular, the HPK 30_LR offer more options.

• Why should the measurement range match the expected pressure?

  A pressure gauge should have a measurement range that reliably covers the expected pressure.
  
  An unnecessarily large measurement range is not automatically the best solution for every measurement task.
  
  For example, in a system with relatively low pressure, a 25- or 100-bar pressure gauge may be more suitable than a 400-bar model.
  
  At the same time, the maximum possible system pressure must not exceed the permissible measurement range.

• Can I use a 400-bar pressure gauge to measure 20 bar as well?

  In principle, any value within the measurement range can be displayed.
  
  For low pressures, however, a smaller measurement range is usually easier and more practical to read.
  
  That is why the HPK 30_LR also includes pressure gauges with ranges up to 25 and 100 bar.

• What does “nominal size 63” mean on a pressure gauge?

  The nominal size describes the size or approximate housing diameter of the pressure gauge.
  
  The HPK test kits use analog pressure gauges with a nominal size of 63.
  
  The nominal size should not be confused with the pressure measurement range.

• Does an analog hydraulic test kit require electricity?

  No.
  
  Pressure is displayed mechanically via the pointer-type pressure gauge.
  
  This means that neither a rechargeable battery nor a regular battery nor an external power source is required for the pressure display.
  
  This is particularly convenient for mobile service calls.

• What is the advantage of an analog pressure gauge?

  An analog pressure gauge allows for direct visual monitoring of pressure via a pointer.

  This makes it possible, for example, to directly track changes during a hydraulic operation.

  In addition, the pressure gauge does not require an electronic power supply.

  If, on the other hand, min/max values, higher digital readability, or additional electronic functions are desired, digital hydraulic test kits for pressure measurements may be the more suitable solution.

• Can pressure fluctuations be detected using an analog pressure gauge?

  Yes.

  If the pressure changes during machine operation, this change can be observed in the movement of the pointer.

  However, very brief pressure spikes or maximum values that need to be documented precisely can be more difficult to capture with an analog pressure gauge.

  For such tasks, digital hydraulic pressure gauges with corresponding min/max functions can offer advantages.

• Can an analog test kit store measurement values?

  No.

  The HPK test kits do not have electronic data logging capabilities.

  The readings are taken directly from the respective pressure gauge.

  If measurement trends need to be recorded and analyzed later, suitable options include, for example, digital hydraulic pressure gauges with data loggers or a digital hydraulic diagnostic device for pressure, flow, and temperature.

• Can I measure two pressures at the same time using an analog test kit?

  With a test kit containing multiple pressure gauges, it is generally possible to incorporate multiple measurement points into a suitably designed test setup.

  This can be useful, for example, to:

  • compare different hydraulic circuits
  • evaluate pressure before and after a component
  • monitor different measurement points under the same operating conditions

  The specific test setup depends on the hydraulic diagram, the measurement task, and the manufacturer’s specifications.

• Can I measure three locations at the same time with the HPK 30_LR?

  The HPK 30_LR includes three pressure gauges with different measurement ranges.
  
  Whether these can be used simultaneously depends on the specific test setup, the available connections, and the respective hydraulic system.
  
  Therefore, the number of pressure gauges available does not automatically mean that every machine should be tested at three points simultaneously.

• Which measuring hoses are included with the HPK test kits?

  The current HPK test kits are available with 2-meter-long measuring hoses.
  
  The HPK 10_LR includes one measuring hose.
  
  The HPK 20_LR and HPK 30_LR each include two measuring hoses.
  
  The hoses allow the pressure gauge to be positioned at a distance from the actual measurement point.

• Why is a hydraulic pressure gauge connected via a measuring hose?

  A pressure hose offers several practical advantages.

  This allows the pressure gauge to:

  • be positioned where it is more visible
  • remain away from moving machine components
  • be used even at hard-to-reach measurement points
  • be monitored more easily while the machine is in operation

  The pressure hose and fittings must be suitable for the respective system pressure.

• Which test connectors are included in the HPK test kits?

  The standard kits include, among other items, test connections with:

  • G1/4
  • M10 × 1

  as well as corresponding reducer adapters.

  Depending on the kit model, additional connection and coupling elements are included.

  Before use, verify which test connection is compatible with the respective machine and measurement point.

• Which adapters are included?

  The current HPK test kits include the following reducers, among other items:

  • G3/8 to M10 × 1
  • G1/2 to M10 × 1

  This allows different connection sizes to be connected to the existing test system.

• What is a direct pressure gauge connection?

  With a direct pressure gauge connection, the pressure gauge can be connected directly to a suitable fitting according to the intended test setup.
  
  Alternatively, the measurement can be taken using a measuring hose.
  
  Which option is best depends on accessibility, the measurement point, and operating conditions.

• How do you connect an analog hydraulic test kit?

  First, the intended measurement point on the hydraulic system is determined.

  Next, the appropriate pressure gauge is connected to the system via:

  • test port
  • adapter
  • measuring hose (if necessary).

  Before taking a measurement, the following must be checked:

  • expected pressure
  • measurement range
  • pressure resistance of the components
  • correct connection.
• Where are the hydraulic test ports located?

  That depends on the vehicle, machine, and hydraulic system.

  Measurement ports can be located, for example, on:

  • hydraulic pumps
  • valve blocks
  • control blocks
  • hoses
  • individual hydraulic circuits

  The correct measurement point should be determined based on the hydraulic diagram or the service documentation.

• Can the pump pressure be tested using an analog test kit?

  Yes.
  
  An analog hydraulic test kit is suitable for checking the pressure at a designated measurement point.
  
  For example, it can be used to verify whether a hydraulic pump reaches the specified pressure under defined conditions.
  
  The measured value must then be compared with the manufacturer’s specified values.

• Is a pressure measurement sufficient for a complete inspection of a hydraulic pump?

  Not always.

  Under certain conditions, a hydraulic pump may still reach the specified pressure while delivering an insufficient flow rate.

  For a more comprehensive performance test, the flow rate should therefore also be measured if necessary.

  Analog hydraulic diagnostic devices for pressure, flow, and temperature or corresponding digital diagnostic systems are suitable for this purpose.

• Can the test kit be used to check a valve's opening pressure?

  If a suitable test setup and a defined setpoint are available for the valve in question, a pressure measurement can help assess its hydraulic behavior.
  
  The specific test depends on the valve design, hydraulic diagram, and manufacturer’s specifications.
  
  The pressure gauge itself does not determine whether a valve is functional or defective.

• Can an internal leak be detected using an analog pressure gauge?

  A pressure measurement can provide clues about unusual system behavior.

  However, a pressure drop alone does not automatically indicate where an internal leak is located.

  Possible causes may include, for example:

  • Hydraulic cylinders
  • Valves
  • Hydraulic pump
  • Hydraulic motor
  • Other components of the circuit

  Further tests are required to determine the exact cause.

• Can a hydraulic system have the correct pressure and still be faulty?

  Yes.

  A correct pressure reading does not automatically mean that:

  • the required flow rate is present
  • the hydraulic oil temperature is correct
  • there are no internal leaks
  • all valves and actuators are functioning properly

  For more complex fault patterns, a hydraulic diagnostic tool for pressure, flow, and temperature should therefore also be used.

• What is the difference between an analog hydraulic test kit and an analog hydraulic diagnostic tool?

  An analog hydraulic test kit focuses on pressure measurement.

  Depending on the kit, various pressure gauge ranges, hoses, and test connections are available.

  An analog hydraulic diagnostic device for pressure, flow, and temperature, on the other hand, also measures:

  • flow rate
  • temperature

  and, in the case of the Leitenberger HD_RFIK200-B-6_LR, also features a load valve.

  The two product groups therefore serve different diagnostic purposes.

• What is the difference between an analog and a digital hydraulic test kit?

  The main difference lies in the pressure display.

  Analog hydraulic test kits use mechanical dial gauges.

  Digital hydraulic test kits for pressure measurements use electronic digital pressure gauges.

  Depending on the model, digital devices may offer additional features such as min/max display.

  Analog pressure gauges, on the other hand, do not require an electrical power supply and provide a direct, traditional pressure reading.

• When should I choose a digital test kit instead of an analog one?

  A digital test kit can be particularly useful when:

  • Measurement values need to be read as clearly as possible in numerical form
  • Min/Max functions are required
  • Digital pressure gauges are preferred in the workshop

  An analog test kit, on the other hand, is well-suited for rugged, direct pressure measurements without an electronic power supply.

  The actual measurement task and the required pressure range are decisive factors in the selection process.

• When should I use a hydraulic diagnostic tool instead of a test kit?

  A test kit is primarily intended for pressure measurements.

  If you also need to determine:

  • how much hydraulic oil is being pumped per minute
  • how the flow rate changes under load
  • what the hydraulic oil temperature is

  then a digital or analog hydraulic diagnostic device for pressure, flow, and temperature is the more suitable product category.

• When is a hydraulic test bench useful?

  A hydraulic test panel provides a clear arrangement of multiple pressure gauges within a single system.

  It can be useful when different pressure ranges need to be quickly accessible on a regular basis.

  A test case, on the other hand, offers the advantage of keeping pressure gauges, hoses, and adapters protected and portable while stored together.

• Can custom analog hydraulic test kits be assembled?

  Yes.

  Leitenberger Automotive Test Equipment also offers custom case configurations upon request.

  This allows the equipment to be tailored, for example, to:

  • required measurement ranges
  • existing machinery
  • special test connections
  • various workshop applications.
• For which vehicles and machines are analog hydraulic test kits suitable?

  Typical applications include, for example:

  • Agricultural machinery
  • Construction machinery
  • Forestry machinery
  • Commercial vehicles
  • Municipal machinery
  • Material handling equipment
  • Stationary hydraulic systems

  The respective pressure ranges and appropriate test connections are critical.

• Are analog hydraulic test kits suitable for agricultural machinery?

  Yes.

  In agricultural machinery, hydraulic pressures can be monitored, for example, on pumps, control blocks, or working hydraulic circuits.

  In electronically controlled machines, mechanical pressure measurement can be effectively combined with the Jaltest Diagnostics for Agricultural Machinery and Vehicles.

• Are the test kits suitable for construction equipment?

  Generally speaking, yes, provided that the pressure range and connections are compatible with the machine in question.

  For electronically controlled construction machinery, the actual hydraulic pressure measurement can also be combined with the Jaltest Diagnostics for Construction Machinery and Off-Highway Vehicles.

• Can electronic vehicle diagnostics replace an analog test kit?

  Not entirely.
  
  For example, an electronic diagnostic system can display a value reported by the vehicle's pressure sensor.
  
  The test kit, on the other hand, allows for an independent physical pressure measurement at the designated measurement point.
  
  This makes it possible, for example, to verify whether an electronically displayed pressure value plausibly matches an external measurement.

• What should be taken into account when performing hydraulic measurements up to 400 bar?

  High-pressure hydraulic systems can pose significant hazards.

  Before each measurement, the following must be checked in particular:

  • the pressure gauge’s permissible measurement range
  • the pressure resistance of the test hose
  • suitable test connections
  • the condition of the connecting components
  • that all connections are properly secured
  • the maximum possible system pressure

  Damaged or unsuitable components must not be used.

• Is it okay to check for a hydraulic leak by hand?

  No.
  
  Hydraulic fluid escaping under high pressure can cause serious injury.
  
  Therefore, do not use your hands or fingers to check for leaks.
  
  Hydraulic tests should only be performed using appropriate equipment and in accordance with the relevant safety and manufacturer’s guidelines.

• For which types of businesses are analog hydraulic test kits particularly useful?

  Analog test kits are particularly suitable for:

  • Agricultural machinery repair shops
  • Construction equipment service centers
  • Commercial vehicle repair shops
  • Forestry and municipal equipment
  • Hydraulic service shops
  • Mobile service technicians
  • Machinery maintenance

  They are especially useful when robust pressure measurements need to be performed regularly on various hydraulic systems and electronic data logging is not required.

  You can find additional solutions under Test and Diagnostic Equipment for Hydraulic Systems.