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Basic Industrial Hydraulics Training Course (MP-10002)


Course Length: 8 hours

Purpose: This course provides comprehensive discussion of the applications of Basic Industrial Hydraulics (MP-10002) as they apply to hydraulic systems. This course is delivered in a format that uses a combination of classroom lecture coupled with a comprehensive component review using real-world products.

This course is taught by highly qualified instructors who are experts in this field. The course covers basic industrial hydraulics including theory, component operation, and fluid power circuits.

This course is recommended for personnel involved in the basic maintenance of hydraulic equipment.


Objectives: Upon completion of this course and with the use of the training manual, students will be able to:

  • Describe fluid power and the components used in the design of hydraulic systems.
  • Identify and explain common hydraulic components.
  • Describe basic hydraulic theory.
  • Explain common circuit applications.
  • Describe preventive maintenance actions .
  • Interpret ANSI symbols and drawings to explain the functions of specific hydraulic systems.
  • Troubleshoot basic common hydraulic components.

Table of Contents

1. OVERVIEW
Introduction 1-1
Fluid Power 1-1
Participant Materials 1-1
Objectives 1-1
Industrial Safety 1-1
Accidents 1-2
Near-Accident 1-2
Accident Prevention 1-2
The People Factor 1-3
Lessons Learned 1-3
Stored Energy System Safety 1-3
Locking Out 1-4
Restoring System Integrity 1-4
Summary 1-5

2. FLUID POWER THEORY
Introduction 2-1
Objectives 2-1
Advantages of Fluid Power 2-1
Transmission of Forces Through Fluids 2-2
Pascal’s Law 2-4
Force and Pressure 2-5
Force and Pressure in Fluid Power Systems 2-7
Multiplication of Forces 2-8
Differential Areas 2-10
Volume and Distance Factors 2-11
Compressibility and Expansion of Gases 2-11
Boyle’s Law 2-11
Charles’ Law 2-13
General Gas Law 2-14
Work and Energy 2-15
Fluid Flow 2-16
Volume and Velocity of Flow 2-17
Steady and Unsteady Flow 2-18
Streamline and Turbulent Flow 2-18
Factors Involved in Flow 2-20
Minimizing Friction 2-23
Advantages of Fluid Power Systems 2-24
Fluid Power Symbols 2-25

3. FLUID SYSTEM COMPONENTS
Introduction 3-1
Regulators 3-1
Valves (Nondirectional Control) 3-6
Manually Operated Valves 3-6
Check Valves 3-9
Solenoid-operated Valves 3-11
Directional Control Valves 3-15
Control Valve Element 3-16
Two-Way Valves 3-17
Three-Way Valves 3-18
Four-Way Valves 3-19
Servo and Proportional Valves 3-25
Five-Way Valves 3-28
Installation Requirements 3-28
Flow Controls 3-28
Pressure-Compensated Flow Controls 3-28
Temperature-Compensated Flow Control 3-30
Meter-in 3-32
Meter-out 3-32
Intensifier 3-32
Cylinders/Actuators 3-33
Ram-Type Cylinders 3-33
Piston-Type Cylinders 3-35
Cushioned Cylinders 3-39
Fluid Pumps and Motors 3-39
Centrifugal Pumps 3-40
Positive Displacement Pumps 3-40
Limited Rotation Actuators 3-54
Purification Equipment 3-56
Hydraulic Liquids 3-74
Types of Hydraulic Liquids 3-78
Piping and Connectors 3-79
Rigid Piping 3-81
Semirigid (Metallic Tubing) 3-82
Tube Fittings 3-84
Hoses 3-86
Sealing Devices 3-87
Materials 3-88
Seal Designs 3-89
Wipers and Backup Washers 3-93
Hydraulic Reservoirs 3-96
Nonpressurized Reservoirs 3-97
Pressurized Reservoirs 3-98
Accumulators 3-99
Weight-Loaded Type 3-99
Air or Gas Type 3-101
Summary 3-105

4. FLUID POWER CIRCUITS
Introduction 4-1
Basic Hydraulic System 4-1
Sample Schematics 4-2
Basic Workstation 4-2
Advanced Workstation 4-3
Multimode Circuit 4-5
Determining Causes of Failures 4-6
Troubleshooting Procedures 4-7
Operating Manuals 4-8
Checking a Control Valve 4-10
Checking Master Control Valves 4-11
Common Causes of Failure 4-13
Dirt 4-13
Heat 4-14
Misapplication 4-14
Improper Fluids 4-14
Maintenance 4-15
Improper Design or Installation 4-15
Summary 4-16




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