Advanced Hydraulic: Theory and Applications

Master Hydraulic Systems, Fluid Power, and Industrial Applications

Claim 2 CPD Points

Platform:

Online

In-class

Revised and Updated: 02 October 2026

Date	Venue	Duration
08 - 09 October 2026	Sandton, Gauteng	2 Days
10 - 11 December 2026	Sandton, Gauteng	2 Days
11 - 12 February 2027	Sandton, Gauteng	2 Days

Course Introduction

Advanced Hydraulic: Theory and Applications is a level 2 training course for equipment maintenance personnel who have attended Basic Hydraulic Training or have equivalent knowledge/experience in hydraulics. This course is also recommended for plant engineering personnel who are tasked with hydraulic system improvement, system modification, and system design. This Advanced Hydraulic: Theory and Applications course builds on the basic hydraulic training course with a more in-depth discussion of the various subjects listed. It also provides a comprehensive discussion of hydraulic components and their operation.

Delegates are equipped with a sound knowledge in the design of hydraulic systems, in order for maintenance staff to extend their technical and methodical knowledge. This enables specific issues relating to maintenance to be dealt with in more detail.

Course Objectives

By attending this Advanced Hydraulic: Theory and Applications training, delegates will be able to understand:

Hydraulic theories and applying them in practice
Hydraulic components and valves
The selection of the correct hydraulic filter for different systems
A brief recap of the operation of pressure, flow, and directional control valves and their applications in hydraulic circuits
Common causes of hydraulic failure and how to prevent them
Hydraulic filters and cleanliness control
Hydraulic pumps and motors and the control thereof
Physical basics of hydraulics and the design of simple hydraulic cylinder systems
Hydraulic cylinder construction and good sealing practices
Calculation of a hydraulic motor application
How to build different types of hydraulic circuits
The different types of hydraulic control systems and the effect on energy usage
Step-by-step building of a hydraulic system

Who should attend?

Advanced Hydraulic: Theory and Applications is suitable to a wide range of professionals but will greatly benefit the technician to the engineer whose job requires an in-depth understanding of designing, evaluating, and applying hydraulic systems efficiently and economically. It is recommended that delegates attending the advanced course should have attended a hydraulics training course or obtained similar experience. People who will benefit from attending this course include:

Plant Managers
Maintenance Managers & Personnel
Filtration, Maintenance & Design Engineers
Millwrights, Pipe Fitters, Plumbers, Mechanics, Machinery Maintenance Mechanics, and Electromechanical Repair Technicians
Anyone responsible for the ongoing operation of a fluid-power system, or who manages or trains workers on such systems

Training Methodology

Our diverse instructional approaches ensure effective learning:

– Lectures & Presentations: Engage with expert-driven, stimulating content.
– Course Material: Access well-crafted supporting resources.
– Group Work: Collaborate on discussions and case studies for practical insights.
– Workshops & Role-Play: Participate in immersive, scenario-based activities.
– Practical Application: Focus on applying theoretical knowledge in real situations.
– Post-Training Support: Receive extensive support after training for skill implementation.

Training Outline

Module 1 — Day 1

The Laws and Principles of Hydraulics

An overview of hydraulic principles, maintenance, and application
Pascal's Law
Computing force, pressure, and area
Bernoulli's Principle
NASA aircraft example
Advantages of hydraulic systems

Causes of Hydraulic Failures

Common system faults
Wear in hydraulics
Hydraulic leaks
Preventive maintenance of hydraulic systems
Finding root causes

Physical Basics of Hydraulics and the Design of a Simple Hydraulic Cylinder System

Categories of actuators, including rotary and linear actuators
Hydraulic cylinder classifications, including single- and double-acting cylinders
Pistons
Cylinder mountings

Calculation of a Hydraulic Motor Application

Hydraulic motors
Limited rotation hydraulic motor
Hydraulic motor performance
Mechanical efficiency
Overall efficiency
Electro-hydraulic stepping motors

Pumps

Hydraulic pumps
Hydraulic pump types, including gear, rotary vane, screw, and radial piston pumps
Pumps for open and closed systems
Multi-pump assembly
Hydraulic pump calculation formulas, including flow, power, mechanical, and hydraulic efficiency

Theory of Fluid, Pressure, Force & Air

Fluid
Characteristics of fluids
Movement of fluid under pressure
Mechanical advantage
Handling of fluids
Fluids used in hydraulics
Flow, force, pressure, and air

Theory of Hydraulic Filters and Cleanliness Control

Filters, including micron rating, beta ratio, and filter location
Filters and contaminants
Cleaning maintenance practice
Cleaning of parts, including seals, oil seal installation, inspecting castings and machined surfaces, gaskets, seal rings, and O-rings
Cleaning and flushing basics for hydraulic systems

Inspections

Daily and monthly checks
Hydraulic systems inspection and service
Start-up and maintenance of hydraulic systems
Maintenance and watchkeeping: simple maintenance hints

Module 2 — Day 2

Thermal Control of Hydraulic Systems

Define and explain heat exchangers
Heat dissipation heat exchangers: air-cooled and water-cooled
Advantages and disadvantages

Hydraulic Components and Valves

Pressure-control valves, including pressure-relief, simple pressure-relief, and compound pressure-relief valves
Directional control valves, including complex valves, poppet valves, sliding-spool valves, and two-way and four-way valves
Control valve repair
Proportional valves, including proportional control valve circuits and circuits with proportional throttle valves
Typical conventional valve circuit with resistive load
Cartridge valves, including slip-in cartridge valves
How to monitor a hydraulic machine's "vital signs"

Hydraulic Accumulators, Circuits, and Control Theory

Accumulators — selection and calculation of size, including weight-loaded, spring-loaded, gas-loaded, non-separator, piston-type separator gas-loaded, and bladder-type separator gas-loaded accumulators
Accumulator applications
An auxiliary power source
Leakage compensator
Hydraulic shock absorber

Step-by-Step Building of a Hydraulic System

Step 1: Understand how a hydraulic system works
Step 2: Determine what type of power source your hydraulic system will require
Step 3: Look at some simple, everyday hydraulic systems to help you become familiar with their function
Step 4: Plan your hydraulic system project with the design parameters you will require
Step 5: Determine the amount of work your system will do to allow you to size the components
Step 6: Choose the appropriate container for your hydraulic fluid reservoir
Step 7: Pick a suitable material to plumb up your hydraulic circuit
Step 8: Find a suitable valve system for your task
Step 9: Select the type and capacity of your hydraulic pump
Step 10: Pair up a suitable motor to your pump
Step 11: Hook up your power application component
Step 12: Build a support frame that will position each component where it will perform its task
Step 13: Fill the system with the hydraulic fluid you choose, bleed the air out of it, then pressurise it to check for leaks

Hydraulic Control Theory

Pressure compensation and load sensing, closed loop and open loop
Control valves
Control components in a hydraulic system
Centering washers
Simple pressure relief valve
Pressure-compensated flow control valves
The hydraulic lever

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FAQs – Advanced Hydraulic: Theory and Applications

Master advanced hydraulic theory and applications covering hydraulic systems, pressure, flow, components, troubleshooting, maintenance, circuit design, and practical industrial applications.

What is covered in the Advanced Hydraulic: Theory and Applications Training?

The course covers advanced hydraulic principles, pumps, motors, valves, filters, hydraulic cylinders, accumulators, hydraulic circuits, control systems, system design, maintenance, and hydraulic failure prevention.

Who should attend the Advanced Hydraulic Training?

The training is suitable for plant managers, maintenance managers and personnel, filtration and design engineers, millwrights, mechanics, plumbers, pipe fitters, electromechanical technicians, and professionals responsible for fluid-power systems.

Does the course cover hydraulic pumps, motors and valves?

Yes. Participants examine different hydraulic pump types, hydraulic motors, pressure and directional control valves, proportional valves, cartridge valves, and their applications in hydraulic circuits.

Does the training cover hydraulic system design and circuits?

Yes. The course covers the design of simple hydraulic cylinder systems, hydraulic circuit construction, component selection, system planning, pump and motor selection, and step-by-step hydraulic system building.

Does the course cover hydraulic maintenance and fault prevention?

Yes. Participants learn about common hydraulic faults, leaks, wear, preventive maintenance, cleanliness control, inspections, filter selection, system flushing, and identifying root causes of hydraulic failures.

Is prior hydraulic knowledge required for this advanced course?

Yes. The course is designed as a Level 2 programme and is recommended for delegates who have completed basic hydraulic training or have equivalent practical knowledge and experience in hydraulics.

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Advanced Hydraulic: Theory and Applications

Master Hydraulic Systems, Fluid Power, and Industrial Applications

Course Objectives

Who should attend?

Course Outline

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Course Objectives

Who should attend?

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Training Outline

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