MEC 409
Hydraulic & Electro-Hydraulic Control Systems (Operation, Troubleshooting & Maintenance)
This course provides participants with a thorough understanding of hydraulic and electro-hydraulic systems, focusing on principles of operation, system components, troubleshooting, maintenance, and fault diagnosis in industrial applications.Participants will learn how to analyze, operate, and maintain hydraulic circuits, pumps, actuators, valves, sensors, and control systems while integrating electrical controls for electro-hydraulic applications. The course combines theory with hands-on exercises to reinforce practical skills.
Duration: 5 days
Prerequisites: Basic Knowledge of mechanical systems and safety practices is recommended
Course objectives
Practical Session:
- Component identification
- Reading and building simple circuits
Practical Session:
- Wiring and operation of electro-hydraulic trainer circuits
Practical Session:
- Start-up, flushing, and commissioning of trainer system
Practical Session:
- Troubleshooting simulated faults
- Maintenance on pump, valves, and actuators
- By the end of this course, participants will be able to:
- Understand hydraulic principles and system behaviour
- Identify and describe hydraulic components (pumps, actuators, valves, accumulators)
- Operate hydraulic & electro-hydraulic circuits safely
- Analyze and troubleshoot mechanical, hydraulic, and electrical faults
- Perform preventive and predictive maintenance
- Interpret hydraulic schematics and electro-hydraulic diagrams
- Optimize system efficiency and reliability
- Apply safety standards and best practices
- Day 1 – HVAC Fundamentals & System Components
- Day 1 – Fundamentals of Hydraulic Systems
- Module 1: Introduction to Hydraulics
- Hydraulic principles: Pascal’s Law, flow, pressure
- Force, work, and power in hydraulic systems
- Types of fluids & properties
- Advantages & applications of hydraulic systems
- Module 2: Hydraulic Components Overview
- Pumps: gear, vane, piston
- Actuators: cylinders & motors
- Valves: directional, pressure, flow control
- Accumulators, filters, reservoirs, and piping
- Module 3: Basic Hydraulic Circuits
- Open-loop vs closed-loop systems
- Symbols & schematic reading
- Basic actuation circuits: single-acting, double-acting cylinders
- Day 2 – Electro-Hydraulic Systems & Controls
- Module 4: Introduction to Electro-Hydraulics
- Definition and benefits
- Electrical control integration
- Solenoids and actuators
- Sensors and feedback devices
- Module 5: Control Elements
- Electro-hydraulic directional control valves
- Proportional & servo valves
- Pressure switches and transducers
- Relays, contactors, PLC interface
- Module 6: Circuit Analysis & Operation
- Valve operation & response
- Circuit sequencing & logic
- Safety interlocks
- Load-sensing systems overview
- Day 3 – Installation, Commissioning & Operation
- Module 7: Hydraulic System Installation
- Pipe/hose selection & layout
- Reservoir sizing & fluid selection
- Pump mounting and alignment
- Filtration & contamination control
- Module 8: Commissioning & Start-Up
- Pressure & flow checks
- Leak detection
- System flushing & filling
- Operational checks & performance verification
- Module 9: Safe Operation Practices
- System pressurization procedures
- Emergency shutdown procedures
- PPE & hazard awareness
- Day 4 – Troubleshooting & Maintenance
- Module 10: Hydraulic Fault Diagnosis
- Low pressure & flow problems
- Excessive heat & noise
- Cylinder sticking or slow movement
- Pump cavitation & leakage
- Module 11: Electro-Hydraulic Troubleshooting
- Solenoid valve failure
- Sensor malfunction
- Electrical control issues
- Intermittent faults
- Module 12: Preventive & Predictive Maintenance
- Scheduled inspections
- Filter replacement
- Oil condition monitoring
- Hydraulic fluid maintenance & contamination control
- Day 5 – Advanced Applications, Case Studies & Workshop
- Module 13: Advanced Hydraulic Applications
- Industrial presses & lifts
- Injection molding machines
- Mobile hydraulics overview
- Module 14: Case Studies
- Real industrial failure examples
- Root cause analysis
- Lessons learned & best practices
- Module 15: Workshop & Capstone Exercises
- Build, test, and troubleshoot a complete electro-hydraulic circuit
- Perform maintenance checks on a trainer system
- Team evaluation & problem-solving