Level 1 Training:BASIC HYDRAULICS TRAINING COURSE (3 days): Typical Content
1.

Self-Assessment Questionnaire
used to support the introduction to hydraulics and identify levels of previous
knowledge and understanding

2.

Introduction to the basic principles of Fluid Power Systems
what is a hydraulic system?
important characteristics of hydraulic systems
where do we use hydraulics?
7 basic principles that underpin hydraulic systems
Pascal’s Law, Force Transmission, Pressure Transmission

3.

Introduction to Circuit Symbols (to current ISO standards)
hydraulic symbols, shape and recognition
how to read hydraulic circuit diagrams
open and closed loop circuits

4.

Pumps-5.

Pressure Control Devices – function, operation and circuit applicationpressure relief valves – direct and pilot operated (including unloading)pressure reducing valvessequence valves

6.

Directional Control Valves – function, operation and circuit application
direct operated and pilot operated
valve sizes and nominal flow rates
poppet valves

7.

Load Holding and Motion Control – function, operation and circuit application
standard check valvespilot operated check valvescounter balance valves

8.

Flow Control Valves – function, operation and circuit application
simple throttle valvesviscosity compensated valvespressure compensated valves
meter in / meter out flow control

9.

Pipes, Hoses and Fittingscompression joints - establishing the perfect connection
knowing the parts and application
hose construction and selection
hose failures and correct installation
safetyMotorsdifferent motor types and basic principal of operation (axial piston, radial piston,
fixed and variable displacement)
shaft speed, displacement, input flow-rate, torque.

10.

different pump types and basic principal of operation (gear, vane, piston)shaft input power and hydraulic output powersuction performance, cavitation, aeration, causes of failure
installation and commissioning

11.

Cylindersdifferent types, basic construction / operation
force, effective area, flow rate and velocity
intensification
regeneration

12.

Accumulators
different types (piston, diaphragm, bladder)
Basic principal of operation
applications
safety and legislation

13.

Hydraulic Oil
important characteristics and different types
additives
viscosity
management control

14.

Contamination Control
origin and nature of contaminants
particle sizes and typical component clearances
establishing target cleanliness levels
monitoring and maintaining cleanliness standards (measurement)
sampling methods

15.

Fault Finding
fault diagnosis, start point and procedures to follow
health and safety and establishing safe working practices
planning and preparation
application of ‘fault-cause-remedy’ techniques

16.

Practical Exercises (in-house training rigs)
performance testing a pumpcomparing the performance of a simple throttle valve to a pressurecompensated flow control valve
to observe and understand pressure intensification
to prepare a set up procedure for three different pressure control valves
with different settings
to build and understand a simple accumulator circuit

17.

Hydraulic Safety
general safety, personal hygiene and handling of oils

Training Certified by the British Fluid Power Association

Level 2 training - please refer to entry requirements.
FAULT FINDING TRAINING COURSE (2 Days): Typical Content
1.

Review of the basic principles of Fluid Power- fundamental principles that underpin hydraulic systems- Pascal’s Law, transmission of force, power- formulae used to calculate flow, pressure, power, torque and force

2.

Maintenance and Fault Finding- maintenance strategies- planning and fault finding techniques- system monitoring- fluid condition- tools and measuring equipment- use of technical reference information

3.

Circuits and Symbols- review of circuit symbols and circuit diagrams- examples of different circuit diagrams- circuit errors- ‘truth tables’ / ‘solenoid charts’4.

Accumulators- basic principal of operation- back up bottles- safety and legislation

5.

Logic Elements- basic function- different types (direction and pressure)- applications

6.

Proportional Valves- basic function- command and feedback signals- diagnostic equipment

7.

Faults and Failures- installation problems- cavitation and aeration- effects of temperature- causes of failures

8.

Hydraulic Oil- contamination control- condition monitoring- sampling methods

9.

Practical Exercises (in-house training rigs)- practical exercises to identify and rectify faults- practise fault finding techniques- use of measuring equipment

10.

Safety- general safety, personal hygiene and handling of oils
- risk assessments- safe systems of work

Level 2 training - please refer to entry requirements.
ACCUMULATOR COMPETENCE TRAINING COURSE (1 DAY): Typical Content
1.

Introduction - Review of the basic principles of Fluid Power Systems- important characteristics of hydraulic systems- basic principles that underpin hydraulic systems- the importance of fluid cleanliness- Pascal’s Law, useful formulas

2.

Introduction to accumulators- history and developments- basic operating principles3.

Gas charged accumulators- gas laws and operating principles- nitrogen- compressibility- gas cylinder - supply options- safe working with Nitrogen4.

Gas charged accumulator types- understanding common terms- details of operation of - Diaphragm, Bladder and Piston accumulators- back-up gas bottles- safety equipment associated with accumulator systems- charging kit- the gas charging process- sources of information

5.

The Pressure System Safety Regulations- the responsibility of users and owners of systems- the written scheme of examination- drawing up a written scheme of examination

6.

Application examples- various examples

7.

Practical exercises- practical exercises to support the topics- practice gas charging- build accumulator circuits

Level 2 training - please refer to entry requirements.
PROPORTIONAL HYDRAULICS TRAINING COURSE (3 Day)TYPICAL CONTENT
A copy of the Bosch Rexroth Vol 2 Training Manual, R900018626, Proportional andServo Valve Technology, is included as part of the course material.
1.

Proportional Hydraulics – An Introduction- overview of ‘on-off’ control and its limitations- introduction to a ‘proportional’ alternative

2.

How Proportional Valves control flow
- the proportional DCV spool- spool characteristics (flow rate, symmetry and notch shape)- symbol recognition

3.

Proportional DCV’s- direct operated and pilot operated DCV’s- feedback and non-feedback valves- describing valve performance in graphical form

4.

Other Proportional Valves and Servo Valves- proportional relief valves and proportional reducing valves- proportional flow control valves- pump and motor displacement controls- overview of high response proportional and servo valves

5.

Control Systems, Input and Output Signals- construction and characteristics of a proportional solenoid- role of the amplifier (deadband compensation, ramp and dither)- input signals and gain control- valve spool feedback transducers and ‘internal closed loop’ control- PID control- overview of pulse width modulation- valves with integral amplifiers

6.

Proportional Valves used in real circuits- oil cleanliness requirements- using pressure compensators- solenoid air bleeds- effect of proportional valves on load control valves

7.

Practical Work- proportional and bang-bang solenoid characteristics- force control, stroke control and hysteresis- proportionality/ramps with DCV and motor circuit- proportional relief valve performance- deadband compensation and gain control- cylinder velocity profile control with 4/3 proportional DCV

Level 2 Training- Fault Finding- Accumulator Competence- Proportional Hydraulics
Entry Requirements
Completion of the Basic Hydraulics course is strongly recommended prior to attending aLevel 2 course. Alternatively, attendees must have sound knowledge/experience of:→→→→→→

the basic principles that underpin all hydraulic systems (relationship between,pressure, flow, force, torque, speed, power);reading and interpreting circuit diagrams using current symbols;
the function and operation of relief, sequence and pressure reducing valves;the principle of pressure compensation relating to flow control; operation of spool
valves; gear, vane and piston pumps;
characteristics of oils and contamination control;
accumulators and their use, safety and legislation.

Certified by the British Fluid Power Association