Hydraulic Fluid Maintenance

Health and Safety Steps

• Maintenance should be performed only by trained personnel

• Never operate the machine if any hydraulic hoses are cracked or broken. Serious personal injury could result.

• The hydraulic fluid in the tank and the various components can cause serious burns. Do not perform any service work without first allowing the oil and corresponding components to cool down to less than 100ºF (38ºC).

Maintenance Technician Signature

The signature of the person performing the job after finishing the health and safetysteps

Supervisor Signature

The signature of the person reassuring Health and Safety procedure steps were followed is Mandatory, (the supervisor can be from any production or maintenance or H&S)

Supervisor Validation

Maintenance Technician followed Health and Safety Steps supposed to be or not?

• Pass
• Flag
• Fail

Perform the following inspection at least once a week. Note that the temperature should be checked daily, before starting the pump each day

• Inspect the hydraulic fluid level

• Inspect the hydraulic fluid temperature

Inspect for hydraulic fluid leaks

Hydraulic fluid leaks are most often due to loosened hydraulic fittings, damaged seals in components, or damaged hoses. If oil appears in excess anywhere on the press, find the source and have a qualified hydraulics technician correct it immediately. Clean up any oil on the press or floor as it is a safety hazard.

• If the machine runs at temperature greater than 160°f (71°C), the hydraulic seals and hoses will harden and rapidly deteriorate, causing frequent leaks

Inspect the Hydraulic hoses

• Any hose which exhibits a lack of flexibility, cracks in the outer casing, punctures or worn areas must be replaced.

Filling the Hydraulic Fluid Level Procedure

• Clean off the filler/breather and surrounding area

• Remove the filler/breather cap

• Insert the funnel

• Add hydraulic fluid until the oil level is shows full on the temperature gauge

• Remove the funnel and replace the filler/breather cap

Replace the filter element

1)With the machine idling and the oil at operating temperature, check the oil filter bypass gauge mounted on the oil filter housing. When the pressure at the incoming side and the outgoing side of the filter are the same, the filter element is clean and the bypass gauge shows green. When the filter becomes dirty, the pressure differential causes the gauge to turn red to remind you to replace the filter element. It should be changed at least once a year. 2)After completely replacing hydraulic fluid, the filter element should be changed before refilling the reservoir AND 3-6 months after the hydraulic fluid is changed. New hydraulic fluid is not always filtered and may wear out the return line filters quickly. 3)The hydraulic fluid filter is designed to filter out harmful particles from the hydraulic system. On the filter, there is an indicator gauge showing the amount of oil bypassing the internal filter element. If the indicator shows a red stripe during operation, it is time to replace the filter element. Refer to the graphic and replace the filter element by following these steps

• Lockout/tagout.

• Remove the 4 bolts holding the filter bowl to the porting head: a) Use a 9/16" socket to turn the bolts counterclockwise, loosening two opposite corners first, then the next two opposite corners. b) The bowl has a spring inside which will slightly push the canister out once the last bolt is loosened, so hold a hand under the canister to catch it

• Discard the old element and the fluid from the filter bowl

• Clean and prepare the canister for reassembly: a) Use a cloth with a non-flammable cleaner (brake cleaner) to clean out the canister, removing any particles along the inside wall. b) Check the O-ring that is located between the canister and the porting head for any damage. Replace if necessary. C) Lubricate the O-rings on the element and on the filter bowl.

• Place the element into the filter bowl with the spring facing down.

• Guide the canister back onto the head, while guiding the element into a pressed fit inside the head. Note: The spring is under compression during this step.

• Place the filter bowl back onto the porting head and tighten the bolts in this pattern: bottom right, top left, top right, bottom left. Do not over-tighten, but ensure consistent tension around the circumference

Tips for Replacing Hydraulic Fluid

1) The acceptable time between hydraulic fluid changes depends on both the fluid used and the operating conditions involved. 2) In general, fluid should be changed when contaminated with water or dirt. Periodic laboratory analysis is the most accurate method to determine when and how often fluid should be changed. The supplier can often run these tests, or check the condition of the used oil. A trained maintenance mechanic can quickly determine the fluid level in the reservoir sight gauge and possible water contamination. Dirt and discolored oil both indicate that the oil should be changed. Additional indicators that the fluid must be changed are unusual noises, excessive temperatures, excessive vibration, leaking lines and fittings, and oil deposits on or around the machine 3) At a minimum, it is recommended to completely drain and replace the hydraulic fluid every year. Always use a hydraulic fluid that matches the specifications

• It is best to change hydraulic fluid when the system is at operating temperature. This will drain off as much of the impurities in suspension as possible.

• To eliminate the possibility of spillage, use a suction pump to remove the fluid from the reservoir. Some suppliers offer this service

• Always replace the return line filter when changing the fluid, and again shortly thereafter.

• Completely drain and refill the reservoir if you change the type of hydraulic fluid in use.

Procedure for Replacing Hydraulic Fluid

1) To refill the reservoir, have the correct amount of clean hydraulic fluid available before starting this procedure. Refer to the reservoir capacity 2) The press requires a complete hydraulic fluid and filter change annually, or every 2,000 hours of operation. Hydraulic fluid does not get dirty like automotive oil, but heat causes the hydraulic fluid to break down and the additives wear out. Although the oil may still look clean, it will not provide adequate lubrication of the hydraulic components. Changing the oil annually will prolong the life of the hydraulic system. 3) New hydraulic fluid is not always filtered and may wear out the return line filters quickly. Ensure that you have a filter to be used as a replacement part shortly after replacing hydraulic fluid

• Travel the press head to the left end of the table

• Move the joystick to the Down position to lower the pressing platen. Press the STOP button just as the platen reaches its lowest position. Do not build up any hydraulic pressure in the Down mode.

• Check the oil temperature on the sight gauge. Allow the oil to cool down to room temperature.

• Lockout /tagout the main power to the machine.

• Clean off the area around the oil filter assembly, inspection cover, and filler/breather

• Remove the hydraulic fluid from the reservoir using one of these methods: a) Drain the hydraulic fluid into a large pan, taking care to protect the floor from fluid spillage. OR b) Pump the hydraulic fluid out through the fill cap . Be sure to remove the breather screen first

• replace the Oil Filter element as instructed

• Refill with Approved hydraulic fluid (Hydraulic fluid will expand when warm. Do not fill completely to the top !!)

• Dispose of used oil and rags in a safe, approved manner

• Replace the filter element again 3-6 months after the oil change occurs.