Basic Hydraulic Troubleshooting Online Training Course

Rated 5.00 out of 5 based on 3 customer ratings
(3 customer reviews)




Basic Hydraulic Troubleshooting

(Approximately 24 – 30 Hours to Complete)

The next best thing to being there!

Since 1994, GPM has been presenting live troubleshooting classes to major corporations such as General Motors, Goodyear, International Paper, Georgia-Pacific and Nissan, to name a few.  Now you can attend the same presentation right at your computer or mobile device at a time that is convenient for you! This online hydraulic troubleshooting course is led by one of GPM Hydraulic Consulting’s finest instructors and consultants, Alan Dellinger.

Short quizzes are interspersed throughout the course to reinforce the knowledge gained from the training modules and the downloadable course materials. Upon completion, the student is given a 50-question final examination. After receiving a passing grade, a custom certificate is generated to prove that the student has attended and passed the nation’s most respected Basic Hydraulic Troubleshooting course.

Why is GPM’s training considered the best by the students who have attended?  First, our instructors are knowledgeable, have in plant troubleshooting experience and know how to teach in a way that is interesting and entertaining.  Secondly, GPM’s superior animation of pumps, valves, accumulators and complete systems are second to none in the industry. Thirdly, examples are used throughout the course of actual hydraulic problems the instructor has encountered and the troubleshooting techniques used to find the problem.

And lastly, the training is specifically designed for electricians, millwrights, supervisors, reliability technicians and anyone who is responsible for the hydraulic maintenance of industrial machinery. This course includes the five things that are needed to troubleshoot and maintain any hydraulic system:

The function of all of the system components

How to read and use the hydraulic schematic as a troubleshooting tool

How to troubleshoot individual components, preferably without removing them from the system

How to properly adjust the system for maximum speed and efficiency

The correct reliability checks to ensure system longevity and uptime

Sample Course Unit

Below is an excerpt from the Pressure Compensating Pumps course unit. Shown below the video is a quiz representative of several throughout the course (not interactive in the sample).

Piston pumps are the most efficient of the three types. Although available in fixed and variable displacements, it is normally used when variable displacement is required over 2000 PSI. Piston pumps are always used in a hydrostatic drive (discussed later in this course). As with the vane pump, the most common method of varying the piston pump displacement is through the use of a pressure compensator. The pump will deliver maximum volume until the compensator setting is reached. At that point, the pump will only supply the amount of oil that the system needs. In the picture above, the pressure compensator on the piston pump is a normally closed valve. The spring behind the swashplate tilts the swashplate at its maximum angle. In the picture above the pistons are fully stroking and the pump is delivering maximum GPM. When the pressure builds to the compensator spring setting (1200 PSI) as shown on the next page, the spool shifts and directs fluid to the stroking piston. The swashplate now moves to the vertical position if no oil is required to operate the system. The piston’s stroke is now near 0, therefore pump volume is near 0 GPM. Only enough oil is delivered to maintain the compensator setting. The piston pump compensator can also stick and cause problems in the system. If the compensator sticks closed, then the pump will continue to deliver maximum volume. A relief valve should be provided immediately downstream of the pump for system protection. If the compensator spool fails open, the pump will compensate at a very low pressure. Taking the compensator off and taking it apart is the best way to check it. The spool will have some very small holes in it, which could plug up with contamination. The spring should also be checked to make sure it is not bent, broken, or warped.

Course Outline

Module 1 Hydraulic Fundamentals

Hydraulic Fundamentals must be understood to troubleshoot hydraulics. This module explains in simple terms the physics that govern hydraulics so the student can understand how the various components function in the system. This enables the student to follow a logical troubleshooting procedure to determine the cause of a failure.

  • Unit 1 Advantages of Hydraulics
  • Unit 2 Compressibility of Fluids
  • Unit 3 Pascal’s Law
  • Unit 4 Conservation of Energy
  • Unit 5 Hydraulic Power
  • Unit 6 Pressure
  • Unit 7 Hydraulic Fundamentals Work Exercises Part I
  • Unit 8 Cylinder Force
  • Unit 9 Pressure Required to Move a Load
  • Unit 10 Hydraulic Fundamentals Work Exercises Part II
  • Unit 11 Volume
  • Unit 12 Cylinder Speed
  • Unit 13 Hydraulic Motor Speed
  • Unit 14 Hydraulic Pipe Size
  • Unit 15 Hydraulic Horsepower
  • Unit 16 Heat and the Hydraulic System
  • Unit 17 Hydraulic Fundamentals Work Exercises Part III

Module 2 Hydraulic Pumps

Hydraulic Pumps are usually the first components changed when a hydraulic problem occurs. The pump should never be changed before making the quick tests taught in this section. A step by step procedure is explained for setting the pump compensator and the system relief valve.

  • Unit 1 Fixed Displacement Pumps
  • Unit 2 Gear Pumps
  • Unit 3 Vane Pumps
  • Unit 4 Relief Valves and Fixed Displacement Pumps
  • Unit 5 Checking the Relief Valve
  • Unit 6 Hydraulic Pumps Work Exercises Part I
  • Unit 7 The Vented Relief Valve and Fixed Displacement Pumps
  • Unit 8 Setting the Relief Valve in a Fixed Displacement Pump Circuit
  • Unit 9 Variable Displacement Pumps
  • Unit 10 Pressure Compensating Pumps – Vane Pump
  • Unit 11 Pressure Compensating Pumps – Piston Pump
  • Unit 12 Compensating Pump Example Circuit
  • Unit 13 Pressure Compensating Pump Settings
  • Unit 14 Hydraulic Pumps Work Exercises Part II
  • Unit 15 Troubleshooting Hydraulic Pump Circuits
  • Unit 16 Visual Checks
  • Unit 17 Sound Checks
  • Unit 18 Troubleshooting Fixed Displacement Pump Circuits
  • Unit 19 Troubleshooting Variable Displacement Pumps
  • Unit 20 Hydraulic Pumps Work Exercises Part III

Module 3 Directional Valves

The purpose of a directional valve usually is to direct flow to cylinders and hydraulic motors. In some cases, they may be used to unload pumps or drain accumulators.

  • Unit 1 Solenoid Operated Valves
  • Unit 2 Solenoid Failures
  • Unit 3 Checking the Solenoid
  • Unit 4 Two-Way Directional Valves
  • Unit 5 Three-Way Directional Valves
  • Unit 6 Four-Way Directional Valves
  • Unit 7 Three Position Valves – Closed Center
  • Unit 8 Closed Center Valves and Cylinder Drift
  • Unit 9 Three Position Valves – Tandem Center
  • Unit 10 Three Position Valves – Open Center
  • Unit 11 Three Position Valves – Float Center
  • Unit 12 Solenoid Controlled, Hydraulic Piloted Valves
  • Unit 13 Common Valve Actuators
  • Unit 14 Troubleshooting Directional Valves and Cylinders

Module 4 Check Valves and Logic Valves

Check valves, the simplest form of directional valves can be used both for directional control and for pressure control. Logic valves are used in many systems to emulate check valves, directional valves, and pressure controls. Mounted in a manifold, they are better suited to high-pressure applications than conventional hydraulic plumbing.

  • Unit 1 Standard Check Valve
  • Unit 2 Spring Loaded Check Valves
  • Unit 3 Pilot to Open Check Valves
  • Unit 4 Pilot to Close Check Valves
  • Unit 5 Logic Valves

Module 5 Pressure Controls

This module focuses upon valves that control pressures in the system. The most common pressure control is the system relief valve which was discussed in the Hydraulic Pumps module and will of course not be repeated here.

  • Unit 1 Pressure Reducing Valves
  • Unit 2 Air Bleed Valves
  • Unit 3 Sequence Valves
  • Unit 4 Counterbalance Valves

Module 6 Accumulators

Hydraulic accumulators store pressurized hydraulic fluid, making it the single most dangerous component in the system. The accumulator performs the same function in a hydraulic circuit that a capacitor does in an electrical circuit.

  • Unit 1 What Accumulators Do
  • Unit 2 Dry Nitrogen Pre-Charge
  • Unit 3 Charging the Accumulator with Nitrogen
  • Unit 4 Checking the Pre-Charge Hydraulically
  • Unit 5 Piston Accumulators
  • Unit 6 Checking the Piston Accumulator
  • Unit 7 Bypassing Test and Piston Removal
  • Unit 8 Undercharged Accumulator
  • Unit 9 Bladder Accumulator
  • Unit 10 Checking the Bladder Accumulator
  • Unit 11 Replacing the Bladder for Bottom Repairable Accumulators
  • Unit 12 Accumulators and Fixed Displacement Pumps
  • Unit 13 Accumulator Dump Valves
  • Unit 14 Accumulators For Shock
  • Unit 15 Accumulator Safety

Module 7 Flow Controls

To control the speed of a cylinder or hydraulic motor, the flow into it must be controlled. One way of doing this is by metering the flow with flow controls. In this module, different types of flow controls are discussed including the ways they may be installed and troubleshooting guidelines.

  • Unit 1 The Three Variables That Affect Flow Through an Orifice
  • Unit 2 Fixed Orifice
  • Unit 3 Variable Orifice
  • Unit 4 Flow Controls and Fixed Displacement Pumps
  • Unit 5 Meter In Flow Controls
  • Unit 6 Meter Out Flow Controls
  • Unit 7 Bleed-Off Flow Controls
  • Unit 8 Pressure Compensating Flow Controls
  • Unit 9 Temperature and Pressure Compensating Flow Controls
  • Unit 10 Flow Controls and Pilot Operated Directional Valves
  • Unit 11 Flow Controls and Suspended Loads
  • Unit 12 Two-Speed Lowering
  • Unit 13 Problems With Flow Controls

Module 8 Hydraulic Motors

Hydraulic motors are rated by their displacement, or how much fluid is required to turn them one revolution. The displacement will thus determine the speed of the motor as well as the torque it can develop. This module includes single and bi-directional motors, internally and externally drained, shock protection, associated pressure controls, speed control, parallel and series installation, and flow dividers.

  • Unit 1 Hydraulic Motors
  • Unit 2 Radial Piston Motors
  • Unit 3 Motors and Crossport Relief Valves
  • Unit 4 Crossport Relief Valve Adjustment Procedure
  • Unit 5 Brake Valve
  • Unit 6 Motor Speed Control
  • Unit 7 Motors in Series
  • Unit 8 Motors in Parallel
  • Unit 9 Flow Dividers and Parallel Motors

Module 9 Servo and Proportional Valves

Servo and proportional valves are used to precisely control the position or speed of an actuator. The valves are different internally but perform the same function. A servo valve normally utilizes an internal mechanical feedback device. Proportional valves usually have an electrical feedback, commonly called an LVDT.

  • Unit 1 Servo and Proportional Valves
  • Unit 2 Servo Valve Operation
  • Unit 3 Direct Operated Valves
  • Unit 4 Two Stage Valves
  • Unit 5 On Board Amplifiers
  • Unit 6 Linear Positioner
  • Unit 7 Valve Amplifier
  • Unit 8 Computer Control
  • Unit 9 Nulling the Servo Valve
  • Unit 10 Servo And Proportional Valve Troubleshooting
  • Unit 11 Checking the Linear Positioner

Module 10 The Hydrostatic Drive

The Hydrostatic drive turns a hydraulic motor at variable speed. A bi-directional, variable displacement pump controls the direction and speed of the hydraulic motor. This type of drive is commonly called a “closed loop” drive. The two ports of the hydraulic pump are hydraulically connected to the two ports on the hydraulic motor forming the closed loop.

  • Unit 1 Main Pump
  • Unit 2 Charge Pump, Relief and Makeup Check Valves
  • Unit 3 Hydrostatic Pump
  • Unit 4 Hydrostatic Drive Crossport Relief Valves
  • Unit 5 Pump Control
  • Unit 6 Typical Hydrostatic Pump
  • Unit 7 Shuttle Valve and Relief
  • Unit 8 Filtration
  • Unit 9 Checking the Hydrostatic Drive

Module 11 Fluid Maintenance

A very large percentage of hydraulic failures are the direct result of improper care of the fluid. This module addresses reservoir components, oil cooling, contamination, fluid sampling, filters, leakage control and many other elements of maintaining fluids for maximum reliability.

  • Unit 1 Viscosity
  • Unit 2 Reservoir
  • Unit 3 Coolers
  • Unit 4 Contamination
  • Unit 5 Sources of Contamination
  • Unit 6 Fluid Sampling
  • Unit 7 System Flushing
  • Unit 8 Filter Selection
  • Unit 9 Filter Placement
  • Unit 10 Maintaining Fluids and FIlters
  • Unit 11 Leakage Control

Module 12 Final Exam

Upon achieving a passing score on the Final Exam, a certificate is generated to prove that you have satisfactorily completed the nation’s most respected Basic Hydraulic Troubleshooting course!

3 reviews for Basic Hydraulic Troubleshooting Online Training Course

  1. Rated 5 out of 5

    Harold Adams

    I have never taken an online course before. I could not have imagined just how much someone can learn this way. I would say that taking this course was almost like actually being in the classroom, but, in a way, this is even better! In a classroom, you can interrupt the whole class and ask a question, but you can’t just rewind the instructor and hear it again the way you can with this. And twice I did have some questions, so I sent emails to ask. Both times, instructor Jack Weeks responded in less than an hour and explained to me in great detail, making certain that I understood.
    I like the blocking quizzes that ensure you understand the key concepts before moving on and, if you miss a question you can review the material and take the quiz over again until you score 100%. This course is truly self paced and the course materials that you download make a valuable reference.
    Most of all, I feel confident now in reading schematics, understanding the functions of all of the components, and following a logical progression of troubleshooting instead of just changing parts that I thought may be bad. This course paid for itself before I even finished it. I set the pressures on our Edger and pre-charged the accumulator according to the steps shown in the course, now the Edger runs faster, quieter and cooler than it has since I have been here. If I had taken this course 6 months ago, it would have saved us from changing a $12,000 pump!
    I’m proud of the certificate I earned in this course and I recommend it for anyone who works on anything hydraulic.

  2. Rated 5 out of 5


    Great course! Everything they said it would be. I learned a lot.

  3. Rated 5 out of 5

    tim (verified owner)

    I think the try before you buy is what pushed me off the fence as I have purchased training material before that I saw later as no value. I thought “if I learn 1 thing the price of the training material would be good”. I think this training material would be a bargain at twice the price! I would like to give Jack a shout out as when I had a issue, you responded very quickly. Thank you for putting this awesome training program together and keeping it easy to follow. Also if you think this is a 1 time shot it is not. I am able to reflect back anytime I want too and the content is even downloadable for easy reference in your toolbox! GREAT VALUE! Get it while the price is a steal!!!

Add a review

Your email address will not be published.