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ICTD International Centre for Training and Development

Operation and Maintenance of Hydraulically Operated Equipment

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Hydraulic equipment in shore based industries is often operated/maintained by personnel who do not possess sufficient knowledge and expertise in this subject.

This often results in expensive breakdowns and machinery downtime.

The course is conducted in a well-equipped laboratory and combines theory lectures and hands-on training in the practical aspects of hydraulics. The practical exercises are performed on a Trainer Panel on which hydraulic principles as well as different types of hydraulic circuits can be demonstrated. The panel is fitted with components manufactured by Vickers, Rexroth, Yuken, and Bosch etc. - all well-known manufacturers of hydraulic equipment.

Computer simulation software is also used, wherein various hydraulic circuits can be simulated in normal and fault-induced conditions. Further, animation of various hydraulic components helps in understanding their working and construction.

Besides, extensive exposure to various hydraulic components such as Direction, Pressure and Flow control valves, pumps, accumulators etc., is provided to enhance understanding of their construction and function in a hydraulic circuit. Thus, the ability to operate hydraulic machinery safely & efficiently, to trace & analyze hydraulic circuits and to troubleshoot logically is gained by the participant.

Course Objectives

Upon successful completion of this course, the delegates will be able to:

  • Learn where and why hydraulics are used in industrial machinery
  • Understand how and why hydraulic systems and components work
  • Learn to read and draw hydraulic schematics
  • Understand the fundamental concepts of hydraulics
  • Identify symbols, trace and analyze circuit diagrams and troubleshoot hydraulic systems logically
  • Understand the working and construction of important hydraulic components commonly used in industrial and mobile applications

Course Outline

Day 1

  • Introductions
  • Definitions of some basic fluid power terms and discussion of some physical concepts as they apply to industrial machinery
  • Explanation of the basic operation of transmitting force an energy through a hydraulic system
  • A discussion of the how and why of cavitation with examples; how it differs from entrained air, and how it can be prevented
  • A discussion of hydraulic fluids
  • An introductory discussion of hydraulic actuators and basic calculations of force, speed, torque and power

Day 2

  • An introduction to hydraulic valves, presentation and discussion of hydraulic symbols
  • Review of previous day’s material and an in-depth activity of developing a simple hydraulic system (log splitter)
  • Movie entitled “Hydraulic Transmission of Power.” An introduction to hydraulic applications
  • Detailed discussion of check valves, cylinders and accumulators – how they work, how they are used in applications, and potential problems

Day 3

  • Detailed discussion of flow control valves. Discussion will involve how they work, how they are applied in circuits, and potential problems
  • Detailed discussion of directional control valves regarding types, applications and some basic troubleshooting
  • Participants connect and operate hydraulic circuits on trainer stands

Day 4

  • Detailed discussion of pressure control valves such as system relief, counterbalance, sequence, unloading and pressure reducing valves. The description of operation and typical applications are discussed
  • Detailed discussion of pilot operated pressure control valves. The description of operation and typical application are discussed
  • Participants connect and operate hydraulic circuits on trainer stands

Day 5

  • Various standard types of hydraulic pumps, their operation and energy saving applications are discussed
  • Hydraulic motor types, their application and operation are discussed
  • Discussion of filtration, sources of dirt and its harmful effects upon hydraulic circuits
  • Course review

Course Methodology

A variety of methodologies will be used during the course that includes:

  • (30%) Based on Case Studies
  • (30%) Techniques
  • (30%) Role Play
  • (10%) Concepts
  • Pre-test and Post-test
  • Variety of Learning Methods
  • Lectures
  • Case Studies and Self Questionaires
  • Group Work
  • Discussion
  • Presentation

Who should attend

This course is intended for maintenance and non-engineering personnel and anyone who desires to increase their basic knowledge of hydraulic components and systems.


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