Welcome to Jessica Ashlock to the IFP Group of Companies! Jessica is from Wichita and will be joining the West team in Outside Sales. Jessica has spent the last five years working in the engineering field and technical sales.
Iowa Fluid Power offers an entry level customer training class specializing in Industrial and Mobile Hydraulic Equipment. This class is intended to address the needs of both maintenance and design personnel to establish a basic understanding of hydraulics.
This training class is highly recommended for those who are new to hydraulic system design, maintenance, and operation. The course also offers valuable insight for those who already have experience in these areas. We cover the general principles of hydraulics throughout this class in a clear and concise manner to provide good groundwork for anyone working with hydraulic systems.
Instructor: Jack May
Training Class at McNeilus Trucks
By the end of the IFP Hydraulics Class, participants should be able to:
- Understand the basics of schematic symbol reading for better troubleshooting and understanding of the machine's operation.
- Understand the differences between the various types of pumps used in hydraulics. Learn how to design and maintain good, cost-effective pumping systems.
- Understand the various pressure control valve types including their schematics and function.
- Understand the importance of hydraulic system filtration and contamination preventative maintenance.
- Become familiar with hydraulic system accessories and their purpose.
- Learn the basic framework of troubleshooting and follow a prescribed method of preventative maintenance and system repair.
1. Hydraulic Schematic Symbols
Schematic symbol reading is a vital troubleshooting skill. Schematic symbols and schematic drawings are very popular in the field of hydraulics.
- The schematic provides a symbolic way to show all the components and connections in a hydraulic system.
- A schematic also allows a skilled reader to understand much of the engineering and operating principals that the machine’s designers intended.
- Your objective is to be able to interpret schematic elements as used in components and system drawings. You’ll learn the basic hydraulic system symbol sets:
- Line styles
- Connected & crossing lines
- Operators – Operators attach components to indicate the methods by which that component is controlled.
- Extra Symbols; i.e. accumulators, cylinders, orifice/flow control, Tank/reservoir, variable or adjustable springs, component rotation, cartridge/logic valve, ball valves and more.
2. Pumps (positive & non-positive pumping systems)
Positive and Non-Positive Pumping tackles the differences between the two types of systems and the design and maintenance needs of each. Cavitation and aeration are addressed as special concerns.
Pump Startup (7 key steps)
- Fill the case
- Block system
- Lower the pump setting
- Set the relief valve
- Pressure relief valves; understand direct acting balanced and pilot operated relief valves plus basic relief valve concepts.
- Pressure reducing valves; understand the basic valve functionality.
- Sequence valves; understand their purpose, design and working principles.
- Unloading valves; learn the differences and similarities of each.
- Counterbalance valves; these valves allow raised loads to be lowered safely with a minimum of wasted energy.
- Directional Control valves; a valve that starts, stops and changes the direction of the fluid. You will learn the types, operators and how they work.
4. Cylinders & Motors
- Types of cylinders
- Special applications
- Cylinder parts
- Common types of hydraulic motors (low/high speed)
- Motor applications
- Key points when specifying
- Pressure gauges
- Desicant breathers
- Heat exchangers
- Pressure switches
6. Troubleshooting Process
- Pump evaluation process
- Filtration/function, application, installation techniques
- Reservoirs/function, application
- Basic hydraulic system operation
- Cleaning of hydraulic systems
- Hydraulic lubrication principals
- Proper PM techniques for hydraulics
Lack of hydraulic system maintenance is the leading cause of component and system failure, yet most maintenance personnel do not understand proper maintenance techniques of a hydraulic system. The foundation to perform proper maintenance on a hydraulic system has three areas of concern: corrective, preventative and predictive.
It takes place following failure or damage, that is, it only occurs when there is an error in the system. This maintenance entails the following consequences:
- Unplanned shutdowns
- At production, it affects production lines
- It means costs due to not budgeted repair and replacement
- The time the system will be out of operation is not predictable
Preventative Maintenance (PM)
Preventive Maintenance of a hydraulic system is very basic and simple and if followed properly can eliminate most hydraulic component failure. Preventive Maintenance is also a discipline and must be followed consistently to obtain results.
Consider a PM program as being performance oriented rather than being activity oriented. Many organizations have good PM procedures but do not require maintenance personnel to follow them or hold them accountable for the proper execution of these procedures. To develop a good preventive maintenance program, follow these steps:
1. Identify the system operating condition.
- Does the system operate 24 hours a day, 7 days a week?
- Does the system operate at maximum flow and pressure 70% or better during operation?
- Is the system located in a dirty or hot environment?
- Identify the system operating condition.
2. What requirements does the Equipment Manufacturer state for Preventive Maintenance on the hydraulic system?
3. What requirements and operating parameters does the component manufacturer state concerning the hydraulic fluid ISO particulate?
4. What requirements and operating parameters does the filter company state concerning their filters ability to meet this requirement?
5. What equipment history is available to verify the above procedures for the hydraulic system?
As in all Preventive Maintenance Programs it’s a good practice to write procedures required for each PM task. Steps or procedures must be written for each task and they must be accurate and understandable by all maintenance personnel from entry level to master technicians. Preventive Maintenance procedures must be a part of the PM Job Plan which includes
- Tools or special equipment required performing the task.
- Parts or material required performing the procedure with store room number.
- Safety precautions for this procedure.
- Environmental concerns or potential hazards.
A list of Preventive Maintenance Task for a Hydraulic System could be:
Preventive Maintenance is the core support that a hydraulic system must have to maximize component life and reduce system failure. Preventive Maintenance procedures that are properly written and followed will allow equipment to operate to its full potential and life cycle.
Predictive maintenance consists of determining the real technical conditions (mechanical and electrical) of the equipment examined, while it is in full operation.
The cause of many breakdowns couldn’t have been prevented with routine maintenance, but could have been caught with a predictive model. In many cases, it doesn’t make sense at all to do PMs from both a cost AND a time perspective. Regarding the preventative maintenance model, there are 3 critical factors in preventative maintenance that you must consider:
- How bad is the worst-case scenario?
- What is the likelihood of a breakdown?
- How much will it cost?
So, how often should you PM? Should you do it every 6 months, every 8 months or maybe every 4 months? This is something that is a bit controversial and needs to be looked at from a cost perspective. At the end of the day, PMs can be expensive if you are over PMing something, but it can help prevent critical failures. However, you also need to consider the fact that even if you PM something, that doesn’t necessarily prevent all failures. You need to make sure you are PMing the right thing and the correct frequency.
Process Cooling Systems/Bearing Lube Cooling Systems/Turbine Lube Systems
Every industry has its unique challenges, but virtually all industries share the goals of increased machine uptime, reduced maintenance, improved safety, energy savings and lower total cost of ownership. Having a reliable machine lubrication system is vitally important. Bearing life is often much better when the bearing is kept clean and well lubricated. However, many applications make good maintenance difficult.
image of custom process cooling lubrication system
Process Cooling System
Process cooling systems provide cooling fluid to a process function. The process starts with the reservoir; it provides some heat transfer, however the majority of cooling starts with heat exchangers. Heat exchangers remove heat from a system by transferring the heat to another media (water or air). Types of heat exchangers may include fan, shell & tube, plate or refrigerated and vary in cost and efficiency. Typically, multiple pumps are used to prevent a single failure from shutting down the system.
Bearing Lube / Cooling System
image of bearing lube skid
Bearing lubrication and cooling skids provide a source of cool clean oil to remove heat from bearings. This extends the life of the system and prevents cost breakdowns. Lube systems typically have the following:
Lube pump and optional backup lube pump
Gravity return ports
Low and kill Level switches
High and kill temperature switches
Output pressure switch and gauge
Turbine Lube System
Turbines require bearings for support during operation. Each of these bearings are supplied with hydraulic oil for lubrication. Hydraulic Lubrication systems are crucial if turbines are to have a long and productive life. However, the oil itself needs to be kept at the right temperature for effective lubrication. EHA-manufactured hydraulic lubrication systems are designed to keep the oil at the right temperature. They typically feature the following components:
- Lube Reservoir that contains the cooling oil for a turbine based pump.
- Electrical emergency backup pump that provides pre-startup lube flow and backup flow in the case of a main turbine pump failure.
- Low & high pressure switches – Learn more about pressure switches for lubrication systems.
- Dual Lube filtration with dirty filter indicators – Lean More
- Pressure gauges before and after main filtration give a visual indication of the pressure
- High Temperature switch and gauge
- Water-to-Oil heat exchanger with water saving and temperature regulation valve
- Lube temperature gauges before and after heat exchanger
- Oil sample port - for easy lab sampling of oil
- Fluid Level indicator
- Turbine Pressure regulator
- Turbine suction and gravity return ports
image of turbine lubrication system
An essential function of accumulators is their ability to store energy. Particularly in cyclic or varying operations, accumulators discharge in times of high demand and recharge during periods of low demand. They are often used to supplement pump flow during peak demand. Without an accumulator, the pump and motor must be sized to handle peak power requirements even if maximum power is only required momentarily. Benefits include:
- Smaller pump that recharges the system during periods of slack demand.
- Smaller motor; a total system that demands less energy & heat and costs less.
- Provides the necessary flow and pressure to retract a cylinder.
- Close a valve.
- Move a machine to a safe position until power is restored or the malfunction is corrected.
- If a lubricant pump fails, the accumulator maintains pressure until the machine stops or a secondary pump restores flow.
- Cushioning "water" hammer effect
- Prevent damage to sensitive components and extend component life and lower maintenance costs.
- Reduce overall hydraulic system noise levels resulting in quieter machines.
When the time comes and you experience cylinder failure, the decision must be made whether to buy new or repair. The benefits of repairing include:
- Shorter lead times
- Significant cost savings over new cylinders
- The ability to identify the cause of failure
Short Turnaround Time
EHA offers quick turnaround on cylinder repair as well as emergency repair service. We understand that breakdowns can occur at any time and when they do you are robbed of your valuable production time and profit. Our in-house machining capabilities are made up of multiple machining centers with experienced technicians They are qualified to rebuild your cylinder to a “better than new” condition. We have a fully equipped repair center with the necessary equipment for repairing cylinders of all sizes wide range of industries.
Save by Repair
Repairing a cylinder can save you approximately 40-50% the cost of new. Although a large portion of the savings comes as a direct result of using many of the existing parts in the repair process, this will not compromise the quality or performance of a repaired cylinder. We test every cylinder we repair. Our testing standards will assure you that your cylinder will be ready for immediate use when it leaves our facility.
Save With Investigative Information
Cylinders sent in for repair receive a thorough inspection at the start of the repair process. During this phase, our technicians check for any stress that may have been placed on the unit from excessive side loads, improper mounting, fluid contamination or defective seals. The information gathered during our inspection may help you adjust and correct issues with your related equipment to extend the life of your cylinders. Simply purchasing new cylinders may not address the specific issues that may lead to repeat failure of the new product.
© 2018 Balluff Inc
Emergency Stop Device
Compact housing for simple installation on various machines and equipment
True Color Sensor BFS 33M
Balluff’s true color sensor uses white LEDs to produce a greater color spectrum evaluation
Magnetically coded Non-Contact safety switch
Non-contact magnetically coded safety switches are outstanding for monitoring guard doors-especially in environments where contamination or dust is expected.
RFID Coded Non-Contact Safety Switch
Tamper resistant, wear free access protection – with a wide range for installation and utilization.
RFID Coded Non-Contact Safety Switch with Optional Latching Force
Tamper-proof, wear-free access security.
© 2018 Balluff Inc
Learn why SAI Hydraulic Motors has been the icon of "power through efficiency" for the past 50 years. Although this story began over 50 years ago, the reason SAI has remained one of the leading companies in the design and production-technology of crankshaft radial piston hydraulic motors has been their advancements in technology year after year. They have specialized in the ability to transform hydraulic power into mechanical power and help designers match overall efficiencies to the application requirements they are seeking. Let's break it down
Hydraulic System Efficiency
This requires hydraulic system designer to first match the motor, then the pump to a specific system performance expectation. Whether the requirement is to do something within a specific time frame, or in handling a given amount of load, the design of the entire system will change depending on the motor selected. That is why the motor selection comes first in the process; you start with the load requirement, then work back to the prime mover—the pump that will put the fluid power into the motor selected to deliver the performance goal.
Each motor type— gear, vane, in-line piston, bent-axis piston and radial piston—has a specific performance profile. So, knowing the application performance requirement and which motor type best meets the objective is the first step. Then it’s necessary to evaluate the design advantages of your motor options along with the degree of complexity you want for the overall system. In the end, it all goes back to the application’s performance expectations.
A hydraulic motor is a hydraulic actuator that, when properly connected into a hydraulic system, will produce a rotary actuation. This can be unidirectional or bidirectional depending on the system design. Motors are similar in design to pumps only where a pump takes a rotary actuation to move hydraulic fluid out of the unit, whereas a motor will take flow into itself and put out a rotary actuation.
Motor Selection Criteria
The application of the hydraulic motor generally dictates the required horsepower and motor speed range, although the actual speed and torque required may sometimes be varied while maintaining the required horsepower.
The type of motor selected depends on the required reliability, life, and performance. But where output speed must be reduced, the overall cost of the motor with speed reduction must be considered to optimize the overall drive installation costs.
Once the type of the fluid is determined, the selection of actual size is based on the expected life and the economics of the overall installation of the machine.
Caution: A fluid motor operating at less than rated capacity will provide a service life extension more than proportional to the reduction in operation below the rated capacity.
Once the type of fluid is determined, the selection of actual size is based on the expected life and economics of the overall installation on the machine.
Caution: A fluid motor operating at less than rated capacity will provide a service life extension more than proportional to the reduction in operation below rated capacity.
SAI Hydraulic Motor Product Features
FEATURE: High Starting Torque
BENEFIT: The SAI motor has virtually the same starting torque and dynamic torque. This is due to the presence of the crankshaft roller bearing. With this, startup friction is greatly reduced.
FEATURE: High Volumetric Efficiency
BENEFIT: In all SAI motor parts under pressure, the sealing is provided by Teflon/elastomer seals. The seal can compensate for the normal wearing of parts, as well as the natural expansion of the parts under stress. This enables SAI motors to maintain excellent volumetric efficiency, even after several thousand working hours. This is especially useful in applications requiring precise speed control at very low speeds or good braking capability.
FEATURE: Contamination Resistance
BENEFIT: The SAI design can withstand very large contamination particles in the system, up to 40 µm. All dynamic parts, such as cylinders, pistons, distributors, and valves, are hardened to further enhance their performance and contamination resistance. Large clearances and seals between dynamic parts also adds to the contamination resistance.
FEATURE: Thermal Shock Resistance
BENEFIT: The large clearances also allow SAI motors to have excellent thermal shock resistance. The large clearances will accept thermal expansion, and will not cause the dynamic parts to come in contact with each other and prolong the life of the motor.
FEATURE: Cavitation Resistance
BENEFIT: The innovative SAI design allows the motor to run in partial or full cavitation. The roller bearing under the piston does not require lubrication, and the piston retaining rings ensure that the pistons remain in firm contact with the central roller bearing. These innovative features allow the SAI motor to operate in full cavitation. The traditional hydraulic motor design with hydrostatic balancing under the pistons require lubrication at all times. If there is no lubrication present, it will experience significant frictional damage.
The wide range range of SAI hydraulic motors including: Variable Displacement, Double Displacement and Fixed Displacement motors, characterized by radial pistons and crankshaft design.
Shaft End Drive Units
SAI offers radial piston motors coupled to single or double stage planetary gearboxes with shaft ends.
Complete Wheel Drives
SAI offers complete wheel motors to be coupled with single or double stage planetary gearboxes and/or drum brakes; compact wheel drive units including planetary gearbox and/or integrated negative disc brakes.
SAI offers shaft end brakes with negative disc.
OTC is the offshore energy industry's premier, global event. Stop by our booth, #8847; April 30th - May 3rd, 2018 at the NRG Arena in Houston. You will see how the manufacturers we are exhibiting this year can make your product perform better, more reliable, and at better price point.
Need a FREE one-day guest pass? It's on us. Just call 713.360.3600 's We'll get you our guest pass guest code!
Some of the Suppliers represented include:
Not going to OTC? Talk to us about our other suppliers like Festo. Their electric drive or gantry can improve your manufacturing processes or allow you to design better machines. Or consider Rotzler Winching Systems for off shore or off road mobile applications. Innovative Fluid Power is your one-stop source for all your fluid power needs.
Manufacturing, Sales & Service
IFP Group of Companies consists of Iowa Fluid Power, Electro-Hydraulic Automation (EHA) and Innovative Fluid Power. EHA, located in Cedar Rapids, Iowa is our world-class manufacturing facility specializing in hydraulics, pneumatics and motion control systems.
Hydraulic power units have been manufactured by EHA for the past 35 years for Industrial and Mobile market applications. We offer:
• Standard base-pak pre-engineered fixed and pressure compensated power units.
• Custom power units to thousands of horsepower.
• Complete systems from fully automated electronic control systems
Through our many supplier affiliations at IFP we can provide the required components to build custom power units designed by EHA’s engineers using electric, gas or diesel prime movers; also experience with (natural & LP) gas applications.
Base-Pak Power Units
• Standard Vertical Units from 3 to 30 Gallon.
• Standard Horizontal Units from 10 to 100 Gallon.
• Standard layouts provide quick delivery in single pieces or large quantities.
• EHA's volume and manufacturing methods will give you the hydraulic flow and pressure that you need at a price
you can afford.
Custom Power Units
• 5 gallon to 5000 gallons.
• Depending on customer preference, components from most of the different major fluid power manufacturers can be used.
• Experienced engineering staff provides quick design turnaround and complete documentation.
• From one unit to one hundred units, we can quickly deliver high quality, long life systems that will power your hydraulic
machines for years to come.
- Hydrostatic and Open Loop hydraulic systems along with
the electronics and the know-how to put together the system that you need.
- Hydraulic systems for a single machine or "central" hydraulic systems to power your entire plant.
- From thousands of horsepower to just a few, EHA can deliver the most efficient up-to-date system that your
- EHA can provide electrical and electronic controls either to interface with your other in-plant systems or as a
Offshore Power Units
- IFP provides an extensive range of hydraulic components from the world’s leading manufacturers.
- EHA designs, manufactures and supplies customized equipment for the offshore industry.
- Our knowledgeable team is available to answer your questions, whether technical or regarding product
- Optimal equipment performance in extreme working conditions, like the offshore industry, is our main
consideration for all our solutions.
Prime Movers (Gas, Diesel or Electric Engines)
- EHA has engineers capable of specifying the HPU components and prime mover type based on torque, speed, and power requirements of the hydraulic power unit and system requirements.
- Prime movers are fully load tested in one of our test cell .
- The completed prime mover is then painted and prepared for shipment
Whether you have very specific needs or you just looking for a high quality standard solution, we provide complete custom built Hydraulic Power Units (HPUs) for every industry, situation and requirement.