COURSE OVERVIEW:

Industrial hydraulic systems are the workhorses of manufacturing and heavy industry, providing precise control and immense power density. This course delivers a high-level practical perspective on the operation of integrated hydraulic circuits, focusing on the synergy between mechanical components and fluid dynamics. Participants will explore the behavior of complex systems under varying load conditions, gaining the expertise required to manage advanced applications such as proportional control and load-sensing technology.

The core of this training is the development of a structured approach to troubleshooting hydraulic malfunctions, which often manifest as heat, noise, or loss of speed. The scope includes the use of diagnostic hardware such as portable flow meters, pressure transducers, and thermal imaging cameras to pinpoint internal leaks and component inefficiencies. By emphasizing a logical "cause-and-effect" methodology, the course enables participants to move beyond part-replacement and toward identifying the true root causes of system failure.

Coverage extends to the maintenance of fluid health and the management of high-pressure safety risks. Attendants will analyze the impact of air entrainment, moisture contamination, and abrasive particles on the lifespan of pumps and valves. The course provides practical exercises in reading complex schematics and setting up control valves for optimal system response. By the end of this program, participants will be equipped to enhance the reliability, safety, and efficiency of the most demanding hydraulic installations.

COURSE OBJECTIVES:

After completion of this course, the participants will be able to:

1.  Analyze complex hydraulic circuit diagrams to predict system behavior.

2.  Evaluate the performance of variable displacement pumps and their controllers.

3.  Diagnose the causes of excessive noise and vibration in hydraulic lines.

4.  Utilize a flow meter and pressure gauge to perform a pump volumetric efficiency test.

5.  Troubleshoot proportional and servo-valve circuits for precision applications.

6.  Identify internal leakage in cylinders and valves through temperature differential analysis.

7.  Optimize the settings of pressure-compensated flow control valves.

8.  Execute safe procedures for accumulator nitrogen charging and maintenance.

9.  Implement a proactive fluid conditioning program to extend component life.

10.  Detect and rectify the causes of hydraulic oil overheating.

11.  Manage the startup and air-bleeding procedures for newly commissioned systems.

12.  Design a logical troubleshooting flow chart for specific plant machinery.

13.  Apply safety protocols for working on high-pressure fluid power systems.

TARGET AUDIENCE:

Senior Maintenance Technicians, Mechanical Engineers, Hydraulic Specialists, and Plant Supervisors involved in the repair and optimization of fluid power machinery.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximise the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and at the end of the course.

COURSE CERTIFICATE:

National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants completing a minimum of 80% of the total attendance time requirement.