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Garnett Cross

Presented by the late Garnett Cross who was an industry leader in hydraulics.

Garnett provided in-person training and consulting for 47 years - 1974 - 2021. His clients included the major corporations in manufacturing, mining, military, shipping and rail.

The training has helped many organizations resolve expensive downtime and ongoing maintenance costs. In addition to the course material, Garnett will share some of my consulting experiences helping get plants back online and resolve ongoing maintenance costs.

Read more

Presented by the late Garnett Cross who was an industry leader in hydraulics.

Garnett provided in-person training and consulting for 47 years - 1974 - 2021. His clients included the major corporations in manufacturing, mining, military, shipping and rail.

The training has helped many organizations resolve expensive downtime and ongoing maintenance costs. In addition to the course material, Garnett will share some of my consulting experiences helping get plants back online and resolve ongoing maintenance costs.

Students from many countries have attended the courses including African states, United States, Emirates, Indonesia, and Europe.

The presentations include animated PowerPoint slides and demonstrations of hydraulic components.

Calculations are provided using metric units.

The course topics include:

  • Principles of Hydraulics

  • Compressibility of Hydraulic Fluid

  • Hydraulic Symbols

  • Two Cylinder Problem

  • Cleanliness of Oil

  • Cleanliness continued

  • Hydraulic and Mechanical Leverage

  • Design of Cylinders

  • Cylinders Oil Capacity

  • Cylinders in Parallel

  • Components of a Hydraulic Circuit

  • Sizing Check-list

  • Pipe sizes for 90 litres/minute

  • Pipe sizing with respect to turbulence of fluid

  • and Reynolds number

  • Hydrostatic Drives

  • Couplings and Reservoirs

  • Hose Identification and Couplings

  • Check Valves and Cartridge Valves

  • Pilot Operated Check Valves

  • Flow Control Valves

  • Pre-fill Valves

  • Directional Control Valves

  • Solenoid Valves

  • Solenoid operated valves with orifice

  • Externally piloted system with throttle plate

  • Gasket mounted relief valve

  • Unloading Valve

  • Fault Finding

  • Sequence Valve

  • Sequencing cylinders with sequence valves

  • Sequence and pressure reducing valves

  • Over center valve with hydraulic motor

  • Vane pump

  • Accumulators

At the end of the course two lectures are provided covering field experience and safety ideas for hydraulic systems.

The course includes resources which can be downloaded for future reference.

An advanced hydraulics course is available, this will help engineers, draftsmen and foremen in the design of hydraulic systems.

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What's inside

Learning objectives

  • How hydraulic systems operate
  • How to read hydraulic circuit diagrams
  • How to keep hydraulic systems operating
  • How to select the correct hydraulic pipes
  • Calculate flow rates and pressures
  • How to trouble shoot hydraulic system issues
  • Using drawings of hydraulic valves and understanding their function

Syllabus

Covers principles, basic hydraulic system and symbols

This lecture covers the basic principles of hydraulics: friction loss in piping, conservation of energy and Pascal's Law.

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Download and print the resource on the lecture for reference.

This lecture covers the Compressibility of Hydraulic Fluids. A large system may require additional oil under pressure. A sudden decompression in a press may result in a cylinder fracturing or pipe joints leaking. The decompression cycle should take place over a period of two to three seconds.

This lecture introduces hydraulic symbols and the method of reading them. To fault find a hydraulic system it is essential to to be able to read a circuit drawing. Calculations to computing the pressure in a hydraulic system are presented.

Download and print out the resources for future reference.

Cleanliness of hydraulic oil is one of the most important aspects of maintaining a hydraulic system to ensure many years of trouble free operation.

Download and print the resource for future reference.

This lecture goes over the need for filters in a hydraulic system and how they are integrated.

This lecture inspects a couple of filters.

Download and print the resource on cleanliness of oil for reference.

This lecture provides an overview of a hydraulic system. Basic components and symbols are presented. The topic of oil flow rates is introduced.

Download and print the resources for future reference.

Be sure to download and print the resources on the lecture for reference.

This lecture starts with presenting how hydraulics is similar to mechanical leverage, where small amounts of oil pumped per rotation of a pump is used to exert a force amplified by the area of a cylinder. The lecture goes in to detail operations of relief valves and directional control valves. The lecture ends with a hydrostatic drive.

This lecture covers the construction of cylinders to enable you to perform maintenance on cylinders like replacing seals.

Download and print the resources for future reference.

Download and print the resources on the lecture for reference.

This lecture covers the challenge of operating multiple cylinders in parallel.

In this lecture a gear pump is opened up to observe the the operation of the pump and highlight the drain port.

This lecture covers using the correct pipe sizes for a hydraulic system. On the suction line under sized pipes will cause cavitation. On the pressure line under sized pipes will cause a high pressure differential which will result in the system overheating and unnecessary power consumption.

This lecture covers a checklist of items to ensure the components of a hydraulic system are the correct size.

Download and print the resources for future reference.

Be sure to download the resources associated with this lecture to help with the quiz and for future reference.

This lecture covers the calculations to correctly size the components for a 90 litre per minute system.

Download and print the resource for future reference.

The lecture covers pipe sizing to avoid turbulence and the calculations to determine turbulence.

This lecture covers the challenge of operating cylinders in series. They must always be operated on at a time.

With the directional valves in the neutral position, the pump flow rate enters port P of the first directional control valve and out of port T to the next directional control valve, entering the P port of the directional valve and is then ported out of port T to the reservoir. This procedure is also used for multiple directional valves connected in series.

This lecture covers how an open circuit hydrostatic drive operates where the return line returns the oil back to tank. A check-list is provided to ensure the components and pipes are the correct size.

What is the meaning of an open circuit drive?

This lecture introduces the internal operation of a piston pump. Covers the following terminology, rotating group, swash plate, balanced pressure and shoe plate.

This lecture covers the design of piston pumps, showing how the internals operate.

This lecture covers piston pump usage in Closed Circuit Hydrostatic Drive.

This lecture covers the closed circuit hydrostatic drive where the pump flow is reversible and the oil can flow in either direction through the pipes. Special bi-directional filters are required so oil always flows in one direction through the filter element.

Download and print the resources for future reference.

This lecture presents the space and vector diagrams for variable hydraulic piston pumps and motors.

A variable piston pump controls the speed and direction of rotation of the connected hydraulic motor.

A variable hydraulic piston motor with a constant flow rate from the pump results in a variable speed and variable torque of the  motor. With a maximum angle on the motor swash plate results in maximum torque and slow rpm, while the minimum angle on the motor swash plate results in high rpm and minimum torque.

This lecture covers inline pumps - piston and gear pumps. Closed loop hydrostatic drives and bi-directional filters are covered in further detail.

This lecture covers the design of gear pumps.

This lecture covers the tight tolerances on gear pumps and to how to bed a new pump in and wether it is best to repair or replace a gear pump.

This lecture covers the dangers of over pressurizing gear pumps.

This lecture is review of a circuit with preset pressure relieve valve and the dangers of adjusting the relief valve to address higher loads.

This lecture covers the viscosity of oil (how thick it is) and temperature affects the viscosity.

What is the determining factor when determining the viscosity of the oil?

The lecture covers the use of high quality couplings to be used to couple the prime mover(electric motor or engine) to the pump to avoid damage to the prime mover and pump. The suggested design of reservoirs is covered.

Download and print the resources for future reference.

Download and print the resources for this lecture for reference.

This lecture coves the identifying marks on hydraulic hoses and shows you how to interpret them. A resource is provided giving details for the safe handling of hydraulic hoses.

Download and print the resource for future reference.

Download and print the resource for the lecture as reference.

This lecture covers check valves and cartridge valves. Details are provided how the valves operate and are used in a hydraulic circuit.

Download and print the resource for future reference.

This lecture covers the operation of pilot operated check valves and how pilot operated check valves may be used for load holding and require positive pilot pressure to move a cylinder.

This lecture covers the operation of flow control valves and how they are used in hydraulic systems for speed control in bleed-off, meter-in and meter-out configurations.

This lecture covers the operation of a prefill valve, how a prefill valve can be used in complex systems to handle high flow rates and high working pressures.

This lecture introduces directional control valves and how they are used to control the flow of oil in a hydraulic system, to control cylinders and hydraulic motors.

This lectures goes over the internals of solenoid valves, operation and installation.

This lectures continues with the internals, operation and installation of solenoid valves.

The lecture starts with the NG10 valve again and continues to discuss flow rates, mounting of the valves and the NG6 valve.

This lecture covers directional control valves for high flow rates which use a smaller solenoid controlled directional control valve to control the larger directional control valve via pilot lines.

This lecture covers directional control valves for high flow rates with a throttling plate between the smaller and larger control valves to adjust the flow of the pilot lines and the speed at which the spool of the larger valve moves. The lecture provides details on how the valves are integrated in circuits.

This lecture goes over a physical NG25 valve which has been cut open to see the internals of the valve.

This lecture goes over a physical NG16 valve and reviews it's operation.

This lecture covers the composite gasket mounted relief valves operate, how to maintain them and how they are used in hydraulic systems.

This lecture covers unloading valves, how they operate and are used in a double pump system for fast approach and slow pressing speed. (High - Low System)

This lecture covers a double pump system with unloading valves for fast approach and slow pressing operations.

This lecture covers both displacement or ram cylinders and regenerating systems.

In a regenerating system design, the pump flow rate is assisted by the oil leaving the cylinder rod end and entering the pump pressure line to increase the cylinder approach speed. In general, an unloading valve is installed in the circuit so as to stop the regenerating process, once the cylinder has contacted the load allowing the cylinder to continue at slow speed and high pressure. 

The pump flow rate is assisted by the oil leaving the cylinder rod end and entering the pump pressure line to increase the cylinder approach speed. In general, an unloading valve is installed in the circuit so as to stop the regenerating process, once the cylinder has contacted the load allowing the cylinder to continue at slow speed and high pressure. 

This lecture proves a valuable step by step approach to fault finding in a hydraulic system.

This lecture introduces sequence valves covering both sequence valves with and without check valves. Sequence valves maintain a minimum working pressure on the primary circuit.

This lecture covers the use of sequence valves, to sequence the operation of cylinders.

This lecture covers the use of sequence valves to make a system operate the heaviest load first.

Say cylinder 1 had 5 MPa; Cylinder 2. had 10 MPa; Cylinder 3 had 15 MPa; and Cylinder 4 had 20 MPa.

This lecture covers pressure reducing valves how they can be used in a hydraulic system to lower the working pressure.

This lecture covers how over center valves can be used to avoid runaway conditions with cylinders - requiring positive pressure to operate the cylinder.

Traffic lights

Read about what's good
what should give you pause
and possible dealbreakers
Provides practical knowledge in hydraulic system maintenance, which is essential for minimizing downtime and reducing maintenance costs in various industries
Includes animated PowerPoint slides and demonstrations of hydraulic components, which can help visual learners grasp complex concepts more easily
Uses metric units for calculations, which may require learners familiar with imperial units to convert or adapt their understanding
Covers a wide range of topics, from basic principles to advanced valve configurations, which builds a strong foundation for both beginners and intermediate learners
Presented by the late Garnett Cross, an industry leader with 47 years of experience, offering insights from real-world consulting experiences
Includes downloadable resources for future reference, which allows learners to revisit key concepts and apply them in practical situations

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Reviews summary

Practical oil hydraulics maintenance

According to learners, this course provides a solid and practical foundation in the maintenance of oil hydraulics. Many appreciate the instructor's deep industry experience and ability to explain complex topics clearly. The coverage of fault finding and detailed component operations like various valves and pumps is frequently mentioned as highly valuable for maintenance professionals. Students find the downloadable resources helpful for future reference. While the course is great for practical application, some learners note that calculations are exclusively in metric units, which might require conversion for those working with imperial systems. Overall, it's seen as a highly relevant training for those involved in hydraulic system maintenance and troubleshooting.
Calculations use only metric measurements.
"All calculations are presented in metric, be prepared to convert if you use imperial."
"Wish there were equivalent imperial unit calculations or a conversion guide included."
"The metric-only approach is consistent but requires extra effort if you're not used to it."
Supplements lectures with helpful materials.
"The downloadable resources are great for reinforcing the lectures."
"Having the symbols and circuit diagrams as resources is very handy."
"Referencing the printed materials helps during the course and afterward."
"I appreciate having the sizing checklists and guides available offline."
In-depth look at hydraulic components.
"The sections on valves (directional, sequence, etc.) were incredibly detailed and useful."
"Understanding the internal operation of pumps was very helpful."
"Goes into sufficient depth on the key parts of a hydraulic system."
"The breakdown of how different valves function is a major strength."
Complex concepts made easy to understand.
"Garnett has a gift for making complex hydraulic principles simple."
"The explanations were clear and easy to follow."
"Despite the technical nature, the material is presented very understandably."
"Found the explanations of hydraulic symbols particularly clear."
Directly applicable to maintenance roles.
"This course is perfect for anyone working in hydraulic maintenance."
"I learned practical steps I can apply immediately on the job."
"Helped me understand the 'why' behind maintenance procedures."
"Focused on real-world issues faced by technicians."
Provides a structured approach to troubleshooting.
"The fault finding section is incredibly valuable for real-world issues."
"Provides a step-by-step method for diagnosing problems in hydraulic systems."
"This troubleshooting guidance is a major takeaway from the course."
"Learning how to approach fault finding systematically was key."
Leverages extensive real-world experience.
"Garnett's decades of experience really shine through in his explanations."
"The instructor shares invaluable consulting experiences that are gold."
"You can tell the trainer knows this stuff inside and out from years in the field."
"His practical examples make the theory much easier to grasp."

Activities

Be better prepared before your course. Deepen your understanding during and after it. Supplement your coursework and achieve mastery of the topics covered in Garnett Cross Training in the Maintenance of Oil Hydraulics with these activities:
Review Hydraulic Symbols
Familiarize yourself with hydraulic symbols to better understand circuit diagrams presented in the course.
Show steps
  • Find a comprehensive hydraulic symbol chart online or in a textbook.
  • Study each symbol and its corresponding component or function.
  • Practice drawing simple hydraulic circuits using the symbols.
Review 'Fluid Power Basics'
Strengthen your foundational knowledge of fluid power with a book covering basic principles and components.
View Fluid Power Basics on Amazon
Show steps
  • Obtain a copy of 'Fluid Power Basics'.
  • Read the chapters covering basic hydraulic principles and components.
  • Pay attention to the explanations of Pascal's Law, flow rates, and pressure.
Review 'Industrial Hydraulic Systems: Theory And Calculations'
Supplement your understanding of hydraulic systems with a detailed textbook covering theory and calculations.
View Alter Ego: A Novel on Amazon
Show steps
  • Obtain a copy of 'Industrial Hydraulic Systems: Theory And Calculations'.
  • Read the chapters relevant to the course topics, focusing on calculations and component sizing.
  • Work through the example problems and exercises in the book.
Three other activities
Expand to see all activities and additional details
Show all six activities
Create a Hydraulic System Diagram
Solidify your understanding of hydraulic circuits by creating a detailed diagram of a system.
Show steps
  • Choose a hydraulic system to diagram (e.g., a simple press or a hydrostatic drive).
  • Identify all the components in the system and their functions.
  • Draw the circuit diagram using standard hydraulic symbols.
  • Label all components and lines clearly.
  • Write a brief description of how the system operates.
Hydraulic Circuit Troubleshooting Scenarios
Practice troubleshooting common hydraulic system faults to improve diagnostic skills.
Show steps
  • Find online resources or textbooks with hydraulic troubleshooting scenarios.
  • Analyze each scenario and identify potential causes of the fault.
  • Develop a step-by-step troubleshooting plan to isolate the problem.
  • Compare your solution with the suggested solution to identify areas for improvement.
Design a Simple Hydraulic System
Apply your knowledge by designing a hydraulic system for a specific application.
Show steps
  • Choose a simple application for a hydraulic system (e.g., lifting a load or operating a clamp).
  • Determine the required force, speed, and stroke length.
  • Select appropriate components (cylinder, pump, valves, etc.).
  • Design the hydraulic circuit diagram.
  • Calculate the required flow rates and pressures.

Career center

Learners who complete Garnett Cross Training in the Maintenance of Oil Hydraulics will develop knowledge and skills that may be useful to these careers:
Hydraulic Technician
A Hydraulic Technician specializes in maintaining, repairing, and troubleshooting hydraulic systems. This role involves diagnosing malfunctions, replacing worn parts, and ensuring systems operate efficiently. This course, with its coverage of hydraulic principles, components, and troubleshooting techniques, directly applies to the daily tasks of a Hydraulic Technician. The course's emphasis on reading hydraulic circuit diagrams and understanding valve functions helps build a strong foundation for diagnosing and resolving hydraulic system issues, essential for success as a Hydraulic Technician. Additionally, the inclusion of field experience insights may provide helpful perspectives on real-world challenges.
Maintenance Engineer
A Maintenance Engineer is responsible for ensuring the reliability and efficiency of machinery and equipment, often including hydraulic systems. This role involves preventative maintenance, troubleshooting failures, and implementing improvements to minimize downtime. This course directly supports the responsibilities of a Maintenance Engineer by providing a solid understanding of hydraulic principles, system components, and fault-finding techniques. By learning how to interpret hydraulic circuit diagrams, calculate flow rates and pressures, and address oil cleanliness, a Maintenance Engineer taking this course will be better equipped to maintain hydraulic systems effectively. The course content on troubleshooting aligns perfectly with the reactive maintenance aspects of this role.
Service Technician
A Service Technician provides on-site maintenance and repair services for hydraulic equipment. This includes diagnosing issues, performing repairs, and ensuring customer satisfaction. This course helps prepare an aspiring Service Technician by covering essential concepts such as hydraulic principles, reading circuit diagrams, and troubleshooting techniques. The course's emphasis on understanding valve functions and identifying hose markings contributes directly to the practical skills needed for this role. The field experience lectures may provide valuable insights into handling real-world service scenarios.
Heavy Equipment Mechanic
A Heavy Equipment Mechanic specializes in maintaining and repairing large machinery that relies on hydraulic systems, such as construction equipment and mining vehicles. This role requires expertise in diagnosing hydraulic problems, replacing components, and ensuring equipment operates safely and efficiently. This course directly supports the career of a Heavy Equipment Mechanic by providing a thorough foundation in hydraulic principles, system components, and troubleshooting techniques. The course's emphasis on reading hydraulic circuit diagrams, understanding valve functions, and addressing oil cleanliness provides the practical knowledge needed to excel in this role. The inclusion of field experience lectures may provide valuable insights into real-world maintenance challenges.
Fluid Power Engineer
A Fluid Power Engineer designs, develops, and tests hydraulic and pneumatic systems for various applications. This role requires a deep understanding of fluid mechanics, system components, and control methods. This course may be useful to a Fluid Power Engineer by providing practical knowledge of hydraulic principles, system design, and troubleshooting. The content on hydraulic symbols, component sizing, and hydrostatic drives can help with the design and analysis of hydraulic systems. The advanced hydraulics course can also give insights into complex system configurations commonly encountered in fluid power engineering.
Manufacturing Engineer
A Manufacturing Engineer improves manufacturing processes and equipment, often including hydraulic systems used in production machinery. This role requires knowledge of system design, maintenance, and process optimization. This course can be valuable for a Manufacturing Engineer by providing a comprehensive understanding of hydraulic systems, from basic principles to advanced configurations. The course content on component sizing, pipe selection, and troubleshooting can help improve the performance and reliability of hydraulic systems in a manufacturing environment. The lectures on cleanliness of oil may be particularly helpful for maintaining system efficiency and preventing downtime.
Hydraulic System Designer
A Hydraulic System Designer creates detailed plans and specifications for hydraulic systems used in various industries. This role requires a strong understanding of hydraulic principles, component selection, and system integration. This course may be useful for an aspiring Hydraulic System Designer by providing foundational knowledge of hydraulic principles, system components, and design considerations. The course content on hydraulic symbols, component sizing, and pipe selection is directly applicable to the design process. The advanced hydraulics course may be especially useful for designing complex hydraulic systems.
Automation Technician
An Automation Technician works with automated systems, many of which rely on hydraulics for power and control. Their responsibilities include troubleshooting, maintenance, and optimization of these systems. This course can be valuable for an Automation Technician by providing a strong understanding of hydraulic principles, system components, and control methods. The course content on hydraulic symbols, directional control valves, and solenoid valves provides a solid foundation for working with hydraulically driven automation equipment. The lectures on fault finding will be helpful for diagnosing and resolving system issues.
Technical Trainer
A Technical Trainer develops and delivers training programs on hydraulic systems for technicians, engineers, and other professionals. This requires a comprehensive understanding of hydraulic principles, system components, and troubleshooting techniques. This course can serve as a refresher for an experienced Technical Trainer or helps build a foundation for someone new to the role. The course material, demonstrations of hydraulic components, and downloadable resources can be valuable assets for developing effective training programs. The syllabus of the course can also point one in the direction of what to teach.
Controls Engineer
A Controls Engineer designs and implements control systems for various industrial processes, which often involve hydraulically actuated equipment. This role requires a strong understanding of control theory, system dynamics, and hydraulic components. This course may be useful for a Controls Engineer by providing practical knowledge of hydraulic principles, system components, and control methods. The content on hydraulic symbols, directional control valves, and solenoid valves can help with the design and implementation of hydraulic control systems. The sections on hydrostatic drives and advanced valve configurations may be particularly helpful for more complex applications.
Plant Engineer
A Plant Engineer oversees the maintenance and operation of equipment within an industrial plant, often including various hydraulic systems. Their duties involve ensuring system reliability, troubleshooting problems, and implementing improvements to maximize efficiency. This course may be useful for a Plant Engineer by offering an overview of hydraulic principles, system components, and maintenance practices. The course content on oil cleanliness, pipe sizing, and fault finding can help in maintaining hydraulic systems effectively. The field experience lectures may provide useful insights for addressing real-world challenges in a plant environment.
Hydraulic Assembler
Hydraulic Assemblers build hydraulic systems and their components according to engineering designs. This could involve anything from assembling pumps, motors, valves, and cylinders to fitting pipes, hoses, and other parts of a hydraulic circuit. Because it covers hydraulic symbols, the principles of hydraulics, and the components of a hydraulic circuit, this course may be useful to a Hydraulic Assembler, from basic principles to advanced configurations. The course content on component sizing, pipe selection, and the numerous visual lectures can help improve the correctness in the assembly of hydraulic systems. The lectures on hose identification can be handy.
Reliability Engineer
A Reliability Engineer analyzes equipment performance data to identify potential failure modes and implement strategies to improve system reliability. This often involves assessing and optimizing hydraulic systems within industrial settings. This course may be useful for a Reliability Engineer by providing a deeper understanding of hydraulic principles, system components, and common failure points. The course content on oil cleanliness, pipe sizing, and fault finding can help with identifying and mitigating potential reliability issues. The field experience lectures may provide valuable insights into real-world maintenance challenges.
Hydraulic Engineering Consultant
A Hydraulic Engineering Consultant provides expert advice and solutions to clients facing technical challenges with hydraulic systems. This role requires a deep understanding of hydraulic principles, system design, and troubleshooting techniques, and often requires an advanced degree. This course, particularly the advanced hydraulics course, may be useful by offering insights from industry experts. The consulting experiences shared in the course may be particularly relevant, offering practical perspectives on resolving real-world problems. The downloadable resources can serve as valuable reference materials for consulting projects.
Technical Sales Engineer
A Technical Sales Engineer sells complex technical products, such as hydraulic systems and components, to industrial clients. This role requires a strong understanding of the products' technical specifications and applications. This course may be useful for a Technical Sales Engineer by providing a deeper understanding of hydraulic principles, system components, and their functions. The course content on hydraulic symbols, component sizing, and various valve types can help in communicating the features and benefits of hydraulic products to potential customers. The field experience lectures may provide valuable insights into real-world applications.

Reading list

We've selected two books that we think will supplement your learning. Use these to develop background knowledge, enrich your coursework, and gain a deeper understanding of the topics covered in Garnett Cross Training in the Maintenance of Oil Hydraulics.
Provides a comprehensive overview of industrial hydraulic systems, covering both theoretical concepts and practical calculations. It serves as a valuable reference for understanding the principles behind hydraulic system design and troubleshooting. The book is particularly useful for reinforcing the course's emphasis on calculations and component sizing. It can be used as a reference text to deepen understanding of the course material.
Provides a foundational understanding of fluid power principles, including hydraulics and pneumatics. It covers basic concepts, components, and circuits in a clear and concise manner. This book is particularly helpful for students who need to strengthen their understanding of the fundamental principles before diving into more advanced topics. It good reference for those new to the field.

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