Dead Ender Pump Maintenance and Repairs
Dead ender pumps are exposed to heavy-duty, continuous operation in challenging work environments. As such, they require frequent maintenance and repairs, ideally provided by an experienced hydraulic technician.
Some forms of hydraulic pump maintenance such as checking hydraulic fluid levels are basic enough for an operator team to handle. However, some advanced maintenance routines require the dead ender pump to be opened up for a detailed inspection. If your hydraulic equipment must be cracked open before the problem can be identified, it’s highly recommended that a knowledgeable hydraulic equipment technician handle the process.
The Importance of Dead Ender Pump Maintenance and Repairs
Dead ender pumps are responsible for tensioning dead end anchor sets – typically at concrete fabrication facilities.
In the field, once the reinforced slab is ready for tensioning, the dead end is left alone while the live end is tensioned. Reliability is a critical feature for dead ender pumps as the dead ends cannot be easily tensioned in the field.
Efficiency is also critical for dead ender pumps because dead ender jacks may tension hundreds (or thousands) of anchor sets with every project. There’s only a handful of seconds available for each anchor, so any interruption during the process can bring operations to an expensive halt.
By ensuring your dead ender pumps are well-maintained and in good repair, your concrete facilities will have a reliability and efficiency advantage. Your dead ender systems will also operate with greater safety.
A Maintenance Checklist for Your Dead Ender Pumps
All hydraulic pumps, including dead ender pumps, require consistent maintenance that should include the following:
- Hydraulic fluid inspections and replacement – Fluid contamination is the number one cause of hydraulic system failures and can ruin a dead ender pump if not addressed promptly. Hydraulic fluid may be affected by solid contaminants – such as dust – or water. Water contamination will cause hydraulic fluid to appear cloudy, while solid contaminants will leave sediment. When sampling hydraulic fluid, it’s strongly recommended that operators take a sample from a test point attached to a working hydraulic line. Using standing oil in the reservoir may produce an inaccurate reading, as any sediment will have likely settled in the bottom of the reservoir.
It’s important to occasionally sample your hydraulic pump’s fluid to verify that it’s not affected by sediment, and to ensure sufficient fluid levels. Consult the dead ender pump’s operating manual for ideal fluid service intervals. - Detailed visual inspections – The first signs of wear or damage are often visible. If your operators remain vigilant to any visible signs of damage, such as leaking hydraulic fluid or signs of corrosion, the problem can be inspected further. During every inspection, check the pump’s body, couplers, reservoir, and any hoses attached to the dead ender pump.
- Check filters, hydraulic lines, and couplers – Your dead ender pump’s filters must be occasionally cleaned or replaced to ensure efficient flow. Failure to do so will eventually lead to contamination separating from the filter and circulating through the system. Some hydraulic pump filters come with built-in indicators that signal when the filter needs a cleaning or a change.
- Check and clean the breather cap and filter – The dead ender pump’s breather cap and filter are responsible for circulating clean air from the environment into the system. It’s also exposed to persistent moisture and dust contamination. Cleaning the breather cap and filter regularly will ensure your dead ender pump, and the fluid it houses, is protected from airborne contaminants.
- Keep an eye on the hydraulic pump’s temperature – If hydraulic fluid exceeds operating temperatures, its viscosity may change and interfere with the dead ender pump’s function. To prevent this, use a thermal gun to take the system’s temperature, being sure to check the heat exchanger’s inlet/outlet ports, the pump body, and the suction side of the pump. If operating temperatures are outside of normal ranges, shut the hydraulic pump down and have it fully inspected by an expert hydraulic equipment technician.
If the above preventative maintenance tasks are performed on time, it will extend the dead ender pump’s lifespan and reliability. Remaining on time with maintenance is critical, which is why it’s a good idea for concrete plants to keep detailed records of all hydraulic equipment maintenance and repairs. A detailed maintenance history will ensure your hydraulic equipment is serviced on time. Maintenance histories are also used to track component replacements, so you’ll know which parts have been replaced, and when. This can help troubleshoot any future problems with the dead ender pump.
Signs That Your Dead Ender Pump Needs Maintenance or Repairs
If there are emerging problems with your dead ender pumps, you’ll likely notice one or more of the following signs, as they indicate potential wear or damage:
- Reduced or inconsistent pressure delivery – If your dead ender pump isn’t coming up to operating pressures as quickly as normal, or if it fails to reach operating pressures at all, this could be a sign of leaks (internal or external), overheating due to fluid viscosity changes, problems with a valve, or excessive component wear.
- Visible leaks or pools of hydraulic fluid – If you can see hydraulic fluid leaking from the dead ender pump, that means contamination can get into the system. Leaks are most common around the pump’s reservoir, near couplers and along hoses. If hydraulic fluid is pooling in areas, don’t assume that the leak is coming from the closest piece of hydraulic equipment. It could be due to a failure elsewhere in the system.
- Cloudy or milky hydraulic fluid – As mentioned above, any sediment in your system’s hydraulic fluid is a sign of solid contamination. This could be dirt or debris that has entered the system, or it could be due to internal wear that has caused sediment to form. Cloudy or milky fluid generally means that water has contaminated the hydraulic fluid.
- Unusual sounds during operation – Dead ender pumps make a lot of noise while they work, but some noises warrant an inspection. This includes whining, banging, or growling noises, which may indicate contamination or cavitation.
If your dead ender teams notice any of the above symptoms, consider scheduling a consultation with an expert hydraulic equipment technician. These issues may indicate a high risk of serious or catastrophic failures, and the earlier they are corrected, the less costly repairs tend to be.
Work with an Expert for Maintenance or Repairs on Your Dead Ender Pumps
At concrete fabrication plants, dead ender pumps are an irreplaceable piece of hydraulic equipment that is vital for tensioning. The more reliable and efficient your dead ender pumps are, the more productive your operator teams will be. The best way to ensure ongoing reliability is to schedule on-time maintenance and respond quickly when a problem emerges. An experienced hydraulic equipment technician can assist with both.