Hydraulic systems are the heart of many roll forming machines, powering cutting units, coil feeding, and press functions. Regular maintenance, including changing the hydraulic oil, is crucial for consistent performance, long component life, and avoiding costly breakdowns.

1. Why Changing Hydraulic Oil Matters

• Prevents Contamination: Over time, hydraulic oil accumulates metal particles, dust, and moisture. Contaminated oil can damage pumps, valves, and cylinders.

• Maintains Viscosity: Old oil can lose viscosity, leading to inconsistent pressure, slower operation, and potential machine damage.

• Protects Seals and Components: Fresh oil prevents premature seal wear and corrosion in hydraulic components.

• Ensures Machine Reliability: Regular oil changes reduce downtime and maintain consistent forming and cutting performance.

Tip: Most machine manufacturers recommend changing hydraulic oil every 2,000–4,000 operating hours, or at least once per year. Check the specific machine manual for exact intervals.

2. Tools and Materials Needed

• Correct hydraulic oil (check machine specifications: ISO VG grade, synthetic vs mineral)

• Oil drain pan or container

• Funnel and clean rags

• Wrenches or socket set for drain plugs and filters

• New hydraulic filters (if required)

• Personal protective equipment (gloves, goggles)

3. Safety Precautions

1. Turn off the machine and disconnect power.

2. Relieve hydraulic pressure: Operate the controls to release stored pressure, or follow the manufacturer’s specific procedure.

3. Work in a clean area to avoid introducing contaminants.

4. Use proper lifting equipment if removing large reservoirs.

4. Step-by-Step Oil Change Process

Step 1: Warm Up the System

• Run the machine for 5–10 minutes to slightly warm the hydraulic oil. Warm oil flows more easily and drains completely.

• Tip: Avoid overheating; the oil should be warm, not hot.

Step 2: Drain Old Oil

1. Place the oil drain pan beneath the reservoir.

2. Remove the drain plug and allow the old oil to completely drain.

3. Remove the return line filter if accessible, and let it drain.

4. Dispose of old oil according to local environmental regulations.

Step 3: Replace Hydraulic Filters

• Remove old filters (spin-on or cartridge type) and install new ones.

• Lubricate the filter seal with fresh oil before installation.

Step 4: Refill with New Oil

1. Use a clean funnel to pour new hydraulic oil into the reservoir.

2. Fill to the recommended level indicated by the sight glass or dipstick.

3. Do not overfill; this can cause foaming and pressure issues.

Step 5: Remove Air from the System

1. Power the machine on without engaging heavy loads.

2. Cycle all hydraulic functions slowly to allow trapped air to escape.

3. Check the oil level again and top up if necessary.

Step 6: Inspect for Leaks

• Check hoses, fittings, and cylinder seals for leaks.

• Tighten or replace any components as needed.

Step 7: Record Maintenance

• Note the date, hours of operation, and oil type used in the maintenance log.

• Regular logs help track oil life and predict future maintenance schedules.

5. Common Mistakes to Avoid

• Using the wrong oil type: Always follow manufacturer recommendations for viscosity and specifications.

• Skipping filter changes: Dirty filters will contaminate new oil.

• Not removing air: Trapped air can cause erratic movements and cavitation.

• Overfilling: Can cause foaming, increased pressure, and damage to seals.

• Neglecting disposal rules: Used hydraulic oil is hazardous and must be disposed of properly.

6. Recommended Maintenance Tips

• Check hydraulic oil level daily or weekly, depending on usage.

• Inspect filters every 500–1,000 hours and replace as necessary.

• Keep the reservoir and surrounding area clean to prevent contamination.

• Periodically test oil for contamination or viscosity breakdown if the machine runs in harsh environments.

Conclusion

Changing hydraulic oil on roll forming machines is a simple but critical task that extends the life of your system, maintains consistent operation, and protects expensive components. By following this guide, operators can perform the task safely, efficiently, and with confidence.

Pro Tip: Pair hydraulic oil changes with other routine maintenance, such as lubrication of rollers and inspection of hoses, for a comprehensive maintenance program.

Hydraulic Oil Change Checklist – Roll Forming Machines

Before You Start

• Turn off the machine and disconnect power

• Relieve all hydraulic pressure (follow machine manual)

• Wear gloves, goggles, and protective clothing

• Prepare drain pan, clean rags, and correct hydraulic oil

Step 1: Warm Up the Oil

• Run the machine 5–10 minutes to warm oil (do not overheat)

Step 2: Drain Old Oil

• Place drain pan under reservoir

• Remove drain plug and let oil fully drain

• Remove return line filter (if accessible) and drain

• Dispose of used oil according to regulations

Step 3: Replace Hydraulic Filters

• Remove old filters

• Lubricate new filter seals with fresh oil

• Install new filters securely

Step 4: Refill with New Oil

• Pour new hydraulic oil into reservoir using a clean funnel

• Fill to manufacturer-recommended level

• Avoid overfilling

Step 5: Remove Air from the System

• Power on machine without heavy load

• Cycle all hydraulic functions slowly

• Check oil level again and top up if needed

Step 6: Inspect for Leaks

• Check hoses, fittings, and cylinder seals

• Tighten or replace leaking components

Step 7: Record Maintenance

• Note date, operating hours, and oil type in maintenance log

• Schedule next oil change and filter replacement

Tips & Reminders

• Always use the oil grade recommended by the machine manufacturer

• Pair oil changes with routine roller lubrication and hose inspections

• Regular maintenance prevents downtime and protects expensive components