BASIC HYDRAULICS TRAINING COURSE (3 Day)

TYPICAL CONTENT

A copy of the Bosch Rexroth Vol 1 Training Manual, R900018614,

Hydraulics, Basic Principles and Components is included as part of the course material.

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

5. Pressure Control Devices – function, operation and circuit application

- pressure relief valves – direct and pilot operated (including unloading)
- pressure reducing valves
- sequence 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 valves
- pilot operated check valves
- counter balance valves

8. Flow Control Valves – function, operation and circuit application

- simple throttle valves
- viscosity compensated valves
- pressure compensated valves
- meter in / meter out flow control

9. Pipes, Hoses and Fittings

- compression joints - establishing the perfect connection
- knowing the parts and application
- hose construction and selection
- hose failures and correct installation
- safety

6 August 2018
10. Motors
- different motor types and basic principal of operation (axial piston, radial piston, fixed
and variable displacement)
- shaft speed, displacement, input flow-rate, torque.

11. Cylinders
- different 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 pump
- comparing the performance of a simple throttle valve to a pressure compensated
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

Certified by the British Fluid Power Association

6 August 2018
PROPORTIONAL HYDRAULICS TRAINING COURSE (3 Day)
TYPICAL CONTENT

This is a Level 2 training course – please see entry requirements over.

A copy of the Bosch Rexroth Vol 2 Training Manual, R900018626, Proportional and Servo
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

6 August 2018
Level 2 Training – Entry Requirements

Completion of the Basic Hydraulics course is recommended prior to attending a

Level 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

6 August 2018
HYDRAULIC SYSTEM DESIGN TRAINING COURSE (3 Day)
TYPICAL CONTENT

This is a Level 2 training course – please see entry requirements over.

A copy of the Bosch Rexroth Training Manual, R90001854, Planning and Design of
Hydraulic Power Systems is included as part of this course material.

1. Basic Hydraulic Design – An Introduction

2. Revision
- pros and cons of ‘hydraulics’ as a power transmission medium
- power transfer and generic design model
- examples to underpin fundamental principles

3. Analysis of Load
- positive and negative (overrunning) loads
- understanding mass and weight
- acceleration forces and equations of motion
- sliding and static friction, effect of inclines, rotary systems

4. Hydraulic Actuators
- cylinder overview
- calculating areas, ratios, speed and forces
- cylinder rod buckling
- hydraulic motor overview and performance graphs
- comparison of different types of hydraulic motors

5. Load Holding and Load Control

- construction and application of pilot operated and overcentre valves
- circuit design with load holding and load control valves

6. Flow Control
- techniques, pumped flow, meter-in/out and bypass
- throttle valve selection
- pressure and temperature compensation
- correct sizing of flow control valves

7. Directional Control
- application and limitations of directed operated DCV’s
- flow forces and compensation in spool valves

8. Pressure Control
- pressure relief and pressuring reducing valve selection

9. Hydraulic Pumps and Prime Movers

- pump, electric motor sizing and selection
- internal combustion engines – modifying hydraulic circuits to suit

10. Reservoirs and Cooling

- functions of the reservoir
- calculating and determining cooling of the reservoir

6 August 2018
 11. Pressure Losses
- sizing pipework, complicated pipe routes
- velocity and pressure drop nomograms; viscosity/temperature diagrams

12. Filters and Filtration

- Overview of filtration systems, media selection and filter grade
- target oil cleanliness, sizing and placing of filter
- clogging indicators, bypass valves and practical considerations in filtration
systems

13. Designer’s Checklist

- common design problems
- understanding components, circuits and component interactions
- defining control to make your circuit work.

Level 2 Training – Entry Requirements

Completion of the Basic Hydraulics course is recommended prior to attending a

Level 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

6 August 2018
FAULT FINDING TRAINING COURSE (2 Day)
TYPICAL CONTENT

This is a Level 2 training course – please see entry requirements over.

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

6 August 2018
 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 – Entry Requirements

Completion of the Basic Hydraulics course is recommended prior to attending a

Level 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.

6 August 2018