Post-tension Jack Maintenance

Post-tension jacks and pumps are operated in rugged conditions where dirt, moisture and other contaminants are everywhere. The general maintenance-related goal is to prevent rough conditions from affecting the post-tension jack. The following maintenance services will help with that:

• Fluid sampling and inspections – Contamination is the number one cause of hydraulic system failures, including post-tensioning jack systems. When contaminants ingress into a post-tension jack, it will accelerate wear to the jack’s internal components – particularly the hydraulic cylinders attached to the jack. Contamination is also a major threat to the hydraulic pump and other in-line components.
  
  Keeping contamination out of your post-tension jack is a never-ending battle, but you can stay on top of it by regularly sampling the hydraulic fluid entering and leaving the post-tension jack. It’s important to test both intake and outflow points as this will help isolate where contaminants are entering the system, if any. When sampling the fluid, look for any visual signs of contamination – a cloudy or milky appearance is a sure sign of problems. The hydraulic fluid may also have an unusual odor.
  
  A fluid sample should be sent to the lab for analysis at least once every few months. Contamination often starts as an invisible issue that lab analysis can catch first.
  
  
• Checking components for wear and necessary replacement – Post-tension jack systems take on a great deal of wear, so occasional component replacement will be necessary to ensure safe, efficient operation. High-wear parts include seals, bearings, gears, the piston rod, the grippers and others. Any part of your post-tension jack system may be affected by excessive wear, which may be the result of typical abrasive or adhesive forces (a result of insufficient lubrication), contamination, overheating hydraulic fluid, cavitation or impact damage.
  
  To inspect for component wear, the post-tension jack and its hydraulic cylinders will need to be opened up for inspection. Look for pitting, scoring or loss of surface texture during your check.
  
  Hydraulic jack assembly or disassembly is a complex process that must be expertly handled to prevent any contaminants from being introduced into the system. If this is beyond your operators’ skill or comfort level, consider partnering with an experienced hydraulic equipment technician for maintenance and repairs.
  
  
• Ensuring the post-tension jack system is properly calibrated – This is a simple step for experienced operators, but it’s always wise to verify that each post-tension jack and pump system is properly calibrated and ready for work. Most of this is done at the hydraulic pump, where the pump’s control value and motor speed are set. Every hydraulic pump is rated by the manufacturer for ideal flow settings, and deviating from them will interfere with the post-tension jack’s function.
  
  It is also important to check hydraulic fluid levels before beginning operation and verify all filters are in good condition and not overly soiled.
  
  If you’re unsure if the post-tension jack is receiving and delivering power efficiently, check the cylinders using a load cell.
  
  
• Scheduling on-time preventative maintenance – Preventative maintenance is the first line of defense against contamination, unusual wear, loss of power and other post-tension jack issues.
  
  It’s highly recommended that contractors keep an updated service history for all hydraulic pumps and jacks, including the post-tension jacks. You can do this with software or on paper, but it’s important to note when each post-tension jack has received maintenance, the nature of that maintenance, and if any issues were noted during service. This will ensure your post-tension jacks are serviced on time.
  
  Consult with the jack’s operating manual to verify service intervals. The basics – fluid changes, visual inspections, fastener tightening – can all be managed by an experienced operator, but any preventative maintenance that involves opening up the post-tension jack may need a skilled hydraulic equipment technician.
  
  
• Partnering with an expert hydraulic technician – An experienced hydraulic technician can provide several maintenance-related benefits to your organization. They can offer prompt preventative maintenance and repairs and perform advanced diagnostics to identify deeper issues with the equipment. They can also provide an expanded inventory of replacement parts for faster service. They may be able to provide replacement equipment if your post-tension jacks experience extended downtime or major failures.
  
  A hydraulic technician partner can be a valuable member of your team, acting as the ultimate go-to professional when dealing with confounding post-tension jack problems.