Course Description

This 36 hour workshop is designed to provide a working knowledge of industrial hydraulics for maintenance and troubleshooting. Participants will learn safe working procedures for maintaining hydraulic systems. They will learn to read hydraulic schematics and identify hydraulic components in a system using schematics. A primary goal is to be able to understand the function and operation of a hydraulic system using schematics.

Various types of hydraulic circuits for cylinders and motors will be covered such as meter in/out, regeneration, pressure reducing, and counterbalance circuits. Participants will use a trainer to assemble the various circuits. They will learn vital skills such as setup and adjustment of pumps, relief valves, flow controls, pressure reducing valves, and pressure compensating valves. They will be able to identify the symptoms of improper adjustments and the effects of contamination.

The main goal of the training is to provide mechanics with the ability to logically identify components that cause various problems. By knowing the symptoms, the mechanic should be able to easily isolate the problem to a couple of components. These components can then usually be checked without removing them from the equipment.

Course Length

36 hours

Course Outline

Hydraulic Principles

• Flow, Pressure, and Force
• Actuator Speeds
• Relationship of Pressure and Flow
• Principles of fluids and fluid flow
• How the components in a hydraulic system operate

Hydraulic Schematics

• Interpreting Hydraulic Symbols
• Reading Hydraulic Schematics
• Basic Hydraulic Circuits
• Interpreting the Operation of Circuits using Schematics

Hydraulic Components

• Positive-Displacement Pumps
• Flow Control Valves
• Directional Control Valves
• Check Valves
• Hydraulic Cylinders
• Hydraulic Motors
• Hydraulic Rotary Actuators
• Pressure Control Valves
• Pilot Operated Pressure Control Valves
• Accumulators
• Fluid Conductors
• Reservoirs, Heat Exchangers and Filters
• Proportional Valves
• Servo Valves

Hydraulic Circuits

• Assemble Hydraulic Circuits using a Trainer
• Adjust Relief Valves, Flow Controls, and Pressure Controls
• Understand Various Types of Flow and Pressure Controls
• Unloading, Sequencing, and Load Sensing
• Effects of Improper Adjustments and Contamination in a Circuit
• Symptoms of Failure
• Basic Hydraulic Troubleshooting

Hands-On Lab Exercises

• Basic troubleshooting requirements
• Principles of fluids and fluid flow
• Principles of motion and force
• Diagnostic equipment
• Noisy pumps, cavitation, aeration
• No system pressure
• Low or erratic system pressure
• No movement of actuator
• Slow or erratic operation of actuator
• System running hot
• Common cylinder problems
• Common cylinder circuit problems
• Solenoid failure

In-Plant Exercises

• Identify system components using schematics
• Monitoring system health using diagnostic tools
• Identifying possible causes of failure
• Methods for rapid troubleshooting without replacing components

Course Requirements

Company must provide detailed company specific or vendor schematics for training.