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Hydraulic Troubleshooting Training Course (MP-10009)

Course Length: 8 hours

Purpose: This course provides comprehensive discussion of the applications of Hydraulic Troubleshooting (MP-10009) as they apply to hydraulic systems. Hands-on training is accomplished through the use of full-size trainers.

This process allows the students to see hydraulic system faults in action and to use a troubleshooting methodology and troubleshooting charts to identify and correct instructor-induced problems in the hydraulic tabletop trainers. This course is taught by highly qualified instructors who are experts in this field. The course covers industrial hydraulics troubleshooting.

This course is recommended for personnel involved in the troubleshooting and repair of hydraulic equipment.


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

  1. Use a typical hydraulic diagram to describe the operation of the system.
  2. Describe the methods used to prevent excessive heat buildup.
  3. Define hydraulic oil contamination.
  4. State the reason for concern about hydraulic oil contamination.
  5. Describe the methods used to prevent hydraulic system contamination.
  6. Describe the troubleshooting methodology.
  7. Use the hydraulic troubleshooting guide to identify various hydraulic problems.
  8. Match the indications of hydraulic actuator problems to causes and corrective actions.
  9. Match the indications of hydraulic pump problems to causes and corrective actions.
  10. Match the indications of hydraulic accumulator problems to causes and corrective actions.
  11. Match the indications of hydraulic valve problems to causes and corrective actions.
  12. Use the hydraulic trainer to match the indications of hydraulic system problems to causes and corrective actions.


Table of Contents

1. System Operations
Objectives 1-1
Hydraulic Circuit Examples 1-1
Directional Mode 1-4
Failure Mode 1-5
Reset Mode 1-5
Heat 1-6

2. System Contamination
Objectives 2-1
Contamination 2-1
Sources of Contamination 2-2
The Impact of Contamination 2-4
Contamination Ratings 2-4
Mechanisms of Wear 2-5
Air Contamination 2-6
Contamination Failures in Components 2-8
Techniques for Minimizing Contamination 2-10
Operations 2-10
Preventative Maintenance 2-10
Repair Maintenance 2-11

3. Troubleshooting Techniques
Objectives 3-1
Troubleshooting Techniques 3-1
Troubleshooting Methodology 3-2
Troubleshooting Using the Seven-Step Method 3-2
Equipment History/Troubleshooting Log 3-9
Troubleshooting Intermittent Failures 3-11

4. Component Troubleshooting
Objectives 4-1
Troubleshooting Preparation 4-1
Checking Faults 4-2
What Do I Check? 4-2
Where Do I Check? 4-3
What Tools Do I Use to Check Measurements? 4-3
What Do I Expect to Read? 4-5
HYDRAULIC ACTUATOR TROUBLESHOOTING 4-5
Cylinders 4-5
Cam-Type Radial Piston Motor 4-6
HYDRAULIC PUMP TROUBLESHOOTING 4-8
HYDRAULIC VALVE TROUBLESHOOTING 4-11
General Valve Troubleshooting 4-11
Direct-Acting Relief Valves 4-11
Pilot-Operated Relief Valves 4-12
Pressure-Reducing Valves 4-12
Flow Control Valves 4-13
Check Valves 4-13
Solenoid-Operated, Direct-Acting Directional Control Valves 4-14
HYDRAULIC ACCUMULATOR TROUBLESHOOTING 4-14




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