90kN Jack Manual

CCL EQUIPMENT MANUAL Stressomatic MKII 90kN Jack
EQUIPMENT MANUAL
CCL STRESSOMATIC MKII 90kN JACK

REVISION 00
Type 90kN
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CCL Stressomatic MKII 90kN Jack

Type
CCL Serial Number
Date
CCL Order Number
CCL Stamp
CCL Stressing Systems Ltd

Registered in England and Wales
Registered Office: Unit 8, Millennium Drive, Leeds, United Kingdom, LS11, 5BP
Registered No: 3959117
Telephone: +44 (0) 113 270 1221
Email: sales@cclint.com
The articles shown are protected by British and International copyright and where appropriate
patent rights and designs rights (registered or unregistered). No reproduction or publication of any
part of this manual may be without prior consent of CCL Stressing Systems Limited nor may any
article shown be made or assembled without such consent. All rights are reserved in the Copyrights
Acts.
This manual is designed to provide skilled and trained operatives with the necessary safety
precautions associated with the installation, use, problem solving and maintenance of the CCL
Stressing Systems’ products. If applied correctly, these instructions can result in a more efficient and
safe working environment and an increased product service life.
All efforts have been made to accurately record all information and data in this manual; however,
CCL Stressing Systems Ltd can neither control the workmanship or conditions under which the
products are used, nor make any guarantee, expressed or implied, regarding the recommendations
contained herein.
Furthermore CCL cannot be responsible for any products altered in the field by misuse or any other
modification. CCL shall not be liable for any damages incurred in connection with the use of the
products or process described herein, including consequential damages. The incorporation by
reference or quotation of material in this manual in any specifications, contract documents,
purchase orders, drawings or job details shall be done at the risk of those making such reference or
quotation and not subject CCL Stressing Systems Ltd to any liability, direct or indirect, and those
making such reference or quotation shall waive any claims against CCL Stressing Systems Ltd.
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CCL Stressing Systems Ltd
CCL products have been providing market leading

quality and service around the world since 1935.
The current CCL Stressing Systems Ltd was formed
in 2000 and operates from Leeds, UK supplying
innovative and reliable solutions for the building
and civil engineering industry.
The current CCL product range reflects over 40

years of continuous development and service. CCL Stressing Systems Ltd has a reputation for quality,
innovation and service. CCL products are in use daily around the world.
Original CCL Equipment
Original CCL equipment is only manufactured by CCL in

Leeds, England. All equipment is produced to CCL’s ISO
9001 quality management systems and in line with the
European CE marking directive.
CCL stressing equipment is widely accepted as the world

leader in design and quality, delivering fast and reliable
service.
The CCL range of stressing equipment is designed

especially for the task and built to exacting standards. It is
valuable equipment and trouble free operation can only be achieved by operators carefully adhering
to these maintenance instructions.
When operated and maintained in line with CCL guidelines the equipment will provide years of
trouble free service.
These instructions should be read entirely before commencing operation and maintenance work. Only
a competent fitter should be employed to dismantle and re-assemble this equipment.
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Contents
1. General Description ........................................................................................................................ 5
1.1 Product Description ................................................................................................................. 5
1.2 Ancillary Equipment Requirements ......................................................................................... 5
2. Standard Nomenclature .................................................................................................................. 5
2.1 Main components of the jack ................................................................................................... 6
3. Specification.................................................................................................................................... 6
3.1 90kN Jack Specification........................................................................................................... 7
3.2 Jack/Pump Cycle Times .......................................................................................................... 8
3.3 Stressing Nose Codes ............................................................................................................. 8
3.4 Jack Wedge Codes .................................................................................................................. 8
3.5 Hose Specification ................................................................................................................... 8
4. Preliminary procedures ................................................................................................................... 9
4.1 Checking the Stressing Nose .................................................................................................. 9
4.2 Removing the Stressing Nose ............................................................................................... 10
4.3 Checking the Internal Jack Wedges ...................................................................................... 11
4.4 Inserting the Internal Jack Wedges ....................................................................................... 11
4.5 Wedge Inspection .................................................................................................................. 12
4.6 Wedge Storage ...................................................................................................................... 15
4.7 Barrel Inspection .................................................................................................................... 15
5. Grip Maintenance ......................................................................................................................... 15
5.1 Grip Cleaning Methods .......................................................................................................... 15
5.2 Wedge Lubrication ................................................................................................................. 17
6. Calibration ..................................................................................................................................... 17
7. General Precautions and Safety ................................................................................................... 17
7.1 Overloading or Improper Use ................................................................................................ 18
7.2 Hose Inspection and Maintenance ........................................................................................ 18
8. Setting Up procedures .................................................................................................................. 19
8.1 Electrical Supply .................................................................................................................... 19
8.2 Connecting The Jack To The Pump Unit ............................................................................... 20
8.3 Amber Flashing Warning Light .............................................................................................. 20
8.4 Pressure Gauge ..................................................................................................................... 20
8.5 Basic operation ...................................................................................................................... 21
8.6 Purging Air from the Pump and Jack Hydraulic System ........................................................ 21
8.7 Stressing the Wire/Strand ...................................................................................................... 22
8.8 Calculating the Applied Load from Wire/strand Elongation ................................................... 22
8.9 De-tensioning of Wire/Strand ................................................................................................ 23
9. Maintenance ................................................................................................................................. 23
9.1 Pre-Maintenance Steps ......................................................................................................... 24
9.2 Servicing the Lock-Off Cylinder ............................................................................................. 24
9.3 Removal of Lock-Off Cylinder ................................................................................................ 24
9.4 Cleaning the Lock-Off Cylinder .............................................................................................. 25
9.5 Re-fitting the Lock-Off Cylinder ............................................................................................. 25
10. Dismantling and Assembly ........................................................................................................... 25
10.1 Dismantling the Lock-Off Cylinder ......................................................................................... 25
10.1.1 Re-Assembling the Lock-Off Cylinder ................................................................................... 27
10.2 Removal of the Lock-off Tube ............................................................................................... 28
10.2.1 Re-Fitting of the Lock-off Tube .............................................................................................. 29
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10.3 Removal of the Barrel ............................................................................................................ 30

10.4 Removing the Piston Tube .................................................................................................... 32
10.4.1 Re-Fitting the Piston Tube ..................................................................................................... 33
10.4.2 Dismantling the Piston Tube and Piston Head ...................................................................... 33
10.5 Removing the Retract Cylinder .............................................................................................. 34
10.5.1 Dismantling the Retract Cylinder ........................................................................................... 35
10.6 Removing the Rear End Cap ................................................................................................. 31
10.6.1 Dismantling the Rear End Cap .............................................................................................. 32
11. Post-Maintenance Safety and Advice ........................................................................................... 35
12. Recommended Spares ................................................................................................................. 35
12.1 Ordering Spares .................................................................................................................... 35
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1. General Description
The 90kNJacks is designed specifically for use in conjunction with CCL Pumps and CCL
grips/anchorages. The grips/anchorages are in turn designed for use with standard prestressing
wire/strand specifications for the manufacture of prestressed concrete.
The main features of the jack are:
• High specification quality materials used throughout.
• Low profile to fit between adjacent wires / strands when stressing.
• Internal oil transfer to avoid risks of possible external pipe rupture.
• Sleek shape to assist when threading through strands.
• Power Lock-off.
1.1 Product Description
This manual covers the following CCL products:-
• 109090 90kN 40cm/15.7in stroke jack designed for stressing tendons of

diameter 3-9.6mm/0.192- 0.378in to a maximum load of 90kN/20200lbf.
1.2 Ancillary Equipment Requirements
To operate the jack you will require the following equipment;

A suitable CCL hydraulic pump such as:-
• CCL SR3000PT pump unit range
• CCL SRX compact pump unit range
• SR4000 pump (need to confirm if this will be designation)
CCL Hydraulic hoses* (or equivalent specification see Section 3.5)

CCL Stressing nose to suit diameter of wire/strand to be stressed
CCL Jack wedge to suit diameter of wire/strand to be stressed
*Note Hydraulic hoses are not included unless a jack & pump are ordered together.
2. Standard Nomenclature
Diagram 2.1 shown below can be used to represent the main components of the 90kN jack
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2.1 Main components of the jack
Rear Handle Hose Connectors
Front Handle
Rear End Cap
Main Cylinder
Lock-off Tube
Stressing Nose
3. Specification
The following chapter includes technical information for the complete range of jacks when operating
with CCL SRX and SR3000PT hydraulic pumps.
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3.1 90kN Jack Specification
SI Units SI Imperial Units Imperial

Maximum design load kN 82 lbf 18434
Maximum extend pressure MPa (bar) 56.5 (565.5) lbf/in2 8200
Max environmental working temp K 323 °F 122
Min environmental working temp K 274 °F 34
Standard retract/lock-off pressure MPa (bar) 15.5 (155) lbf/in2 2250
Maximum retract/lock-off pressure MPa (bar) 56.5 (565.5) lbf/in2 8200
Standard lock-off load kN 5.0 lbf 1124
Wedge set (at lock-off) mm # +/- # in ## +/- ##
Initial take up extension mm ## in ##
Working extension per bite mm ### in ##
Total extension mm 400 in 15.7
Standard extension rate (SRX) mm/s 23 in/s 0.9
Standard retraction rate (SRX) mm/s 40 in/s 1.6
Standard extension rate (SR3000PT) mm/s 67 in/s 2.6
Standard retraction rate (SR3000PT) mm/s 57 in/s 2.2
Standard extension rate (SR4000PT) mm/s To Test in/s To Test
Standard retraction rate (SR4000PT) mm/s To Test in/s To Test
Mass of jack kg 19 lb 42
Ram area extend mm 1461 in 2.3
Ram area retract mm 833 in 1.3
Lock-off ram area mm 313 in 0.5
SI (mm) Imperial (in)

A Minimum length of wire 160 6.3
B Length of jack fully retracted 1163.5 45.8
C Maximum width 139 5.5
D Distance from bottom to centre of jack 50 2.0
E Overall height of jack 193 7.6
F Diameter of main cylinder 65 2.6
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3.2 Jack/Pump Cycle Times
Extension Time (s) Retract Time (s) Complete Cycle Time (s)
Pump Type
SRX 17 10 27
SR3000 6 7 13
SR4000 To Test To Test To Test
*Note: Times quoted are when jack is unloaded
3.3 Stressing Nose Codes
Strand/Wire Diameter
Stressing Nose Assembly Code Part Number
Jack Type mm in
HD3 Plywire 109158
3-7 0.118-0.276
XL2/XL3 Wire/HD2 Plywire 109159
90kN
8/9.6mm XL3 109160
8-9.6 5/16-3/8
8/9.6mm XL 109161
3.4 Jack Wedge Codes
Strand/Wire Diameter
Wedge Code Part Number
Jack Type mm in
3-4 0.118-0.157 A3-5mm 101028
5 0.196 5mm 109155
6 1/4 6mm 109156
90kN
7 0.276 7mm 109157
8 5/16 8mm 605227
9.3/9.6 3/8 9.6mm 605228
3.5 Hose Specification
The hoses supplied by CCL (part no. 149506) for use with this jack conform to; “The supply of
machinery (safety) regulations 1992” (EC machinery directive-for portable equipment). All hoses are
tested prior to shipping & are fully traceable.
*NOTE. Hoses are only supplied if a jack is purchased with a CCL pump.
Only CCL supplied hoses or equivalent quality hydraulic hoses should be
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used with CCL equipment. If in doubt contact CCL.
Nominal Bore (A) 3/8in

Fittings (B) 3/8in BSPF
Working pressure 690bar/10000psi
Bursting pressure 2760bar/40000psi
4. Preliminary procedures
The following chapter contains information concerning preliminary safety procedures which should
always be carried out prior to operating the equipment.
4.1 Checking the Stressing Nose
Before any stressing operation it is very important to check that the correct type of stressing nose is
fitted to the jack. Identification marks are stamped on the conical face of the stressing nose (see Fig
4.3.1), which relate the size & type of CCL anchorage to which they are suited. The tables in sections
3.5, 3.6 and 3.7 contain information regarding stressing nose codes.
Fig 4.3.1
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4.2 Removing the Stressing Nose
The following section contains number references shown alongside the diagrams -e.g. Main cylinder
(1). These numbers relate to the corresponding components shown in the general assembly
drawings included at the end of this manual.
The expressions “unscrew” or “tighten” refer to right handed threads unless otherwise stated.
Stressing Nose (22)
Main Cylinder (1)
Lock-off Tube (2)
Lock-off Cylinder (3)
• Grip the jack by the main cylinder (1) in a shielded vice (rubber plates or similar soft material
which will not damage the main cylinder should be used).
• Unscrew the stressing nose (22) by placing a steel rod through the tool-point holes in the
nose. The lock-off cylinder (3) should be kept from rotating by gripping the flats whilst
unscrewing the stressing nose (22)
Lock-off Spring (20)
Lock-off Piston (4)
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• Once the stressing nose has been removed care should be taken to keep the lock-off piston
(4) and lock-off spring (20) clean and free from debris.
• To re-assemble, ensure the lock-off piston (4) and lock-off spring (20) are in position and
screw the stressing nose (22) into the lock-off cylinder (3) using a steel rod through the tool-
point holes in the nose.
4.3 Checking the Internal Jack Wedges
It is important to check the correct internal wedges are fitted to the jack and that they are in an
appropriate condition for stressing operations.
The internal jack wedges are roll marked on the outer cylindrical face as shown above. The markings
relate to the diameter of strand/wire for which the wedge is designed. Table 3.4 contains
information regarding wedge markings/sizes and the relating part numbers.
In order to check the internal jack wedges, the spring tube assembly must be removed.
*NOTE: Before commencing with any maintenance operation ensure the instructions listed in sections 9 and
9.1 have been followed.
Once the spring tube assembly is removed from the jack, withdraw the wedges (21) by tilting the
jack vertically.
The wedge segments can now be removed from the O-ring for inspection. If the wedges are being
changed it is important to check that the correct stressing nose is fitted to the jack.
4.4 Inserting the Internal Jack Wedges
• Remove any oil from the internal bore and external tapers of the wedges (21).
• Ensure the wedges have been treated with lubricant (see Section 5.2) and the wedge O-ring
is positioned within the groove on the rear of the wedges (21).
• Insert wedges smallest end first into the rear end of the retract cylinder (17).
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• Push the wedge down the retract cylinder (17) and into the piston tube (9), all the way into
the barrel (7).
• When the wedge (21) is seated correctly in the barrel (7), screw the spring tube retainer (20)
into the retract cylinder (17).
4.5 Wedge Inspection
It is impossible to predict the exact number of uses that can be expected of CCL grip components
(wedges, circlips and barrels) due to the many different variables associated with the prestressing
process. However, CCL would recommend that the internal wedges of the jacks are inspected and
cleaned at least once a day, and that the following procedures are practiced in order to maximise
the lifespan of the grip components and to minimise the possibility of failures.
The wedge should produce a good even bite within the wire or strand. Checking the wire or strand
after stressing is a good indication of the effectiveness, therefore the condition of the grip.
Well defined bite marks on wire/strand indicate the grips are in good condition.
Note the defined sharp profile of the teeth imprint on the strand.
Visually inspect for cracking
Some longitudinal cracking can occur, and will vary in intensity depending on the exact diameter of
the strand being used. Incorrect strand/wire diameter or an uneven build up of release agent can
cause cracking. CCL recommend that wedges with cracks are discarded before the cracking becomes
excessive (see below).
Visually Inspect threads
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The wedge teeth are designed to embed or bite into the prestressing strand. After prolonged use
the teeth on the wedge become worn. The degree of wear is related to the wedges ability to grip
the wire/strand during stressing. Highly worn threads can lead to wire/strand slippage during
stressing, it is therefore important to inspect the wedge threads after each operation to reduce the
chances of this occurring.
An example of good sharp wedge teeth
Wedge teeth are worn down and rounded, reducing the effectiveness of the bite. CCL would
recommend wedges in this condition be discarded.
Wedge teeth are chipped and some are missing, if more than 20% of
the teeth appear chipped the segment should be discarded.
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The deformation seen on this wedge was caused by the strand

slipping through the grip during tensioning. This happened because
the wedge teeth were in poor condition as described above, and
could not effectively hold the strand while it was placed under
tension.
Visually inspect for corrosion
Corrosion of the outer smooth tapered face of the wedge results in higher friction between the
wedge and barrel. This can cause improper wedge seating or prevent the wedge releasing from the
barrel. Corrosion of the wedge teeth can cause insufficient embedding into the prestressing strand,
leading to possible strand slippage.
Cleaning the wedges as described in Section 5.1 will normally

eliminate any surface corrosion. If problems persist then the
cleaning process should be reviewed. Proper inspection,
maintenance and lubrication prevent build-up of corrosion by-
products and minimize these problems.
Visually check for contamination
Dirt or concrete contaminants in the wedge teeth and outer surface of the taper will interfere with
the gripping operation and cause serious problems. Contaminants can usually be removed using the
cleaning methods described in Section 5.1
Clean Teeth Grease/Oil Dirt/Dust Concrete

Ingress Ingress Ingress
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4.6 Wedge Storage
When not in use wedges should be cleaned, inspected and lubricated (see Section 5.2) to prevent
corrosion and stored in a dry contaminant free environment. It is important to store cleaned inspected
wedges which are ready for operation separately from any other wedges, eliminating the possibility
of any damaged/contaminated wedges being re-used for stressing operations-potentially causing
problems.
Even with good maintenance and inspection procedure, over time the wedge teeth will wear and
strand/wedge debris can form within the teeth.
4.7 Barrel Inspection
The taper bore of the barrel must be clean and free from cracks,
dents, rust and concrete debris.
An example of a good barrel showing an unmarked smooth bore with
no outer deformation
The images above show barrels with severe internal scoring. This is caused by over-use, and foreign
objects within the barrel. The scoring effect is accelerated by tensioning without sufficient lubrication.
Barrels in this condition should be discarded.
5. Grip Maintenance
This chapter contains information on the various aspects of maintaining the internal grips of the jack.
5.1 Grip Cleaning Methods
The internal grip components of the jack should be fully cleaned as often as possible. Care should be
taken to clean all rust, dirt and concrete debris from the external taper and internal teeth of the
wedges along with the internal bore of the barrels.
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There are three different cleaning methods available depending on the quantity of grips to be
cleaned along with the time and manpower available.
Cleaning brushes
CCL supply a variety of cleaning brushes to suit the range of

wedges and barrels available. They are designed to fit most
drill chucks-and will efficiently remove debris from both
wedge teeth and internal barrel bores.
Ultrasonic Tank
The contaminated grip components are placed in the tank

along with CCL ultrasonic cleaning fluid. The cleaning time will
vary depending on the severity of contamination.
Ultrasonic tanks are available in a range of sizes.
Wetblast Machine
The Wetblast machine uses a water/glass media slurry to remove

grease and other contaminants such as dried concrete deposits
from the grip components. The process is highly effective and
efficient as a large number of components can be cleaned
simultaneously.
Wedges before cleaning Wedges after cleaning
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5.2 Wedge Lubrication
Once the wedges have been cleaned their outer taper should be lubricated with CCL
release agent to ensure the wedges easily release the tendon after each stressing
operation. This is a specifically formulated molybdenum based lubricant which dries
around ten
minutes after application to form a hard coating. Jacks come supplied with their
internal wedges pre-lubricated in this way and to maintain proper operation CCL advise
that wedges are re-lubricated every 250 bites or daily. Care should be taken not to
apply too much lubricant to the surface of the wedges as this could potentially cause
problems, also, ensure that the lubricant has dried before re-assembling.
6. Calibration
Calibration of any CCL jack must be carried out along with a pump so that the relationship between
the hydraulic pressure supplied by the pump and the consequent force exerted by the jack can be
defined.
If the jack supplied by CCL was bought in conjunction with a CCL pump then the equipment will
already have been calibrated before shipping, and a corresponding calibration certificate supplied.
Calibration of the jack to the corresponding pump pressure

gauge should be carried out as regularly as possible so that
the application of accurate prestressing loads is maintained.
CCL advise that equipment be calibrated once every twelve
months at the absolute minimum, no matter how little the
equipment has been used.
CCL can supply the necessary equipment to carry out a
calibration, and also operate a calibration service from the
UK factory.
Digital Calibration Kit. Part No. 116039
7. General Precautions and Safety
Stressing of wire/strand is extremely dangerous and should only be carried out by persons suitably
qualified in the use of the equipment, and with the necessary safety procedures to protect both the
operators and non-involved personnel. These procedures have been formulated in accordance with
the "Management of Health and Safety" and "Provision and Use of Work Equipment Regulations
1992"
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7.1 Overloading or Improper Use
• Overloading or improper use could lead to FATAL injury.

• The load applied to the wire or strand should never exceed 80% of the manufacturer's
certified minimum breaking load.
• The load should never exceed the specified design load of the jack (see Sections 3.1, 3.2 and
3.3).
• The hydraulic pressure should never exceed the specified maximum pressure of the jack (see
Sections 3.1, 3.2 and 3.3).
• Never use the equipment outside the safe environmental working temperature (see
Sections 3.1, 3.2 and 3.3).
7.2 Hose Inspection and Maintenance
It is necessary to carry out the following regular inspection procedures (particularly as the hose
assembly is likely to be used under arduous conditions) to ensure the hoses remain in a safe
operational state. These inspections shall be carried out by a competent person properly trained
and familiar with the operational use of the equipment.
• Before use
o Ensure that only hoses, couplings
and fittings provided by CCL
Stressing Systems are used or
components of equivalent quality
and specification.
o Ensure that the couplings are
securely attached to the hose.
o Ensure that anti-kink springs are fitted on all hoses and hose assemblies and that they
are in their correct location and are firmly attached to the ferrule.
o Ensure that the hose is free from

cuts, abrasions, kinks and other
irregularities which could impair its
performance.
• During use
o Ensure that the hose is not bent
beyond the minimum bend radius
of 70mm.
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o Avoid twisting, knotting or trapping

the hose.
o Avoid handling the hose

unnecessarily whilst under
pressure.
o DO NOT use the hose as a means of
moving either the pump or the
jack.
o Hose assemblies should NOT be used as a means to hold tools in position especially
whilst under pressure.
• After use
o Before disconnecting the quick release connectors ensure that there is no residual
pressure in the hydraulic system (see Section 8).
o Remove the anti-kink springs and visually inspect the joint at the connection of the hose
to the ferrule.
o Visually inspect the whole length of the hose for signs of cuts, abrasions and any other
mechanical or chemical damage.
o Reconnect anti-kink spring.
• For hose that has satisfied the visual inspections identified above, the following pressure
test shall be conducted as regularly as possible.
o With the hoses disconnected from the jack, pressurise the complete assembly to the
maximum working pressure of the pump.
o Maintain this pressure for 5 minutes. De-pressurise the hose.
o Repeat this pressure test for a further 5 minutes and visually inspect for signs of leakage.
If any leakage occurs, the hose should be withdrawn from service immediately and
returned to the supplier for inspection.
o Thermoplastic hose should be withdrawn from service after 8 years, regardless of the
condition.
8. Setting Up procedures
This chapter contains information on how to safely set-up the jack and pump provided the
information contained in the previous chapters has been adhered to.
8.1 Electrical Supply
If the jack has been supplied with a pump unit, the directions given in the corresponding pump
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manual should be followed for wiring up the pump. CCL recommend the fitting of an earth leakage
protection device to the incoming power supply of all electrically operated pump units.
8.2 Connecting The Jack To The Pump Unit
It is important that only CCL fittings or components of equivalent quality and specification are fitted
at the jack head. These are supplied fitted to the jack as shown below. The hoses connect directly
to these fittings. Failure to observe this could damage the jack beyond repair and may cause an
accident.
Retract
Extend
The port on either the SRX or SR3000PT pump labelled retract must be connected to the retract port
on the jack. The port on either the SRX or SR3000PT pump labelled extend is connected to the
extend port on the jack. The extend and retract ports on the jack are indicated by markings on the
main cylinder pipe cover (15)
Failure to connect the hoses correctly could lead to premature failure of the internal jack tubes, with
potentially dangerous consequences. Use the protective dust-caps if disconnecting the hoses, dirt
entering these connectors could lead to a blockage, and subsequent overload.
8.3 Amber Flashing Warning Light
If fitted to the pump, make sure the light is operational when the pump is energised.
8.4 Pressure Gauge
Position the pump unit so that the pressure gauge is in the direct line of sight of the operator. This is
to ensure that an accurate reading of the gauge value can be obtained.
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8.5 Basic operation
The following instructions are for information only and should be read in conjunction with the CCL
operation and maintenance instructions for the SR3000PT, SR4000 and SRX pumps. Wire or strand
anchorage systems must only be used as instructed by their supplier and must not be used for any
other purpose. Where anchorages or gripping devices not manufactured by CCL are used, it is the
responsibility of the end user to ensure that they are suitable for use with the CCL jack.
8.6 Purging Air from the Pump and Jack Hydraulic System
• Connect the hoses as described in Section 8.2 and ensure the inspection guidelines listed in
Section 7.2 have been followed.
• Connect the pump control box to the socket at the front of the pump unit.
Once the jack is connected the system can be purged of air using the following procedure.
• First fully unscrew the main relief valve on the pump.
• Press the extend button on the pump control box to start operation.
Retract (Black)
Extend (White)
Pump control box
• Screw the main relief valve clockwise until the jack retract cylinder begins to move, the
retract cylinder will extend and may jump due to air in the ram. This is normal for a jack the
first time it is used.
• Once the jack reaches the end of its stroke and the retract cylinder stops moving screw the
main relief valve clockwise one full turn. The pressure gauge will show an increase in
pressure.
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• Release the extend button and press the retract button, the lock-off piston in the front of
the jack will extend and after a 2 second delay the retract cylinder will begin to retract.
• Once the retract cylinder is fully retracted (i.e. it has stopped moving) release the retract
button-there is now no pressure in the hydraulic system.
• The jack can be cycled in and out several times as described above to purge all the air in the
system.
• Once the jack extends and retracts smoothly the system is free from air.
NOTE: When pressing the retract button with no strand and load on the jack the outer tube will extend for 2
seconds before retracting, this is normal and does not occur when stressing strand.
8.7 Stressing the Wire/Strand
Now the hydraulic system between the pump and jack is free from air, stressing of the wire/strand
can commence.
• Thread the fully retracted jack onto the wire/strand nose-first and support using the jack
handles. Care must be taken not to bend or kink the strand.
• The desired load which is to be applied to the wire/strand should be translated to a
corresponding pressure value using the calibration certificate.
• To begin stressing the white (extend) button is pressed, the pump unit runs and the jack
extends-pulling the wire/strand through the anchor grip.
• If there is a large amount of slack it may not be possible to reach the required stressing
pressure, hence apply the required load to the wire/strand within the first full extension of
the jack. If this is the case, after completing a full stroke the jack should be retracted by
pressing the black (retract) button, then pushed up to the back of the anchor grip, and
further pulls taken until the required load is achieved.
• Once the required load has been achieved it should be checked that the jack is not at the
end of its stroke (i.e. fully extended) as this may give a false pressure reading. If in doubt the
jack should be retracted and another bite of the strand taken.
8.8 Calculating the Applied Load from Wire/strand Elongation
CCL recommend that the wire/strand extension is recorded during stressing so that calculations can
be carried out to verify that the load applied to the wire/strand is as expected. To calculate the load
the following equation is used.
E  A e Where: F = Applied load (N)

F=
L E = Modulus of elasticity of wire/strand (N/m2)
A = Nominal cross-sectional area of wire/strand (m2)
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e = Extension of wire/strand (m)

L = Original length of wire/strand (m)
* NOTE. The modulus of elasticity ( E ) and nominal cross-sectional area of the wire/strand ( A ) should be
obtained from the manufacturer’s technical specification.
8.9 De-tensioning of Wire/Strand
A range of de-tensioning noses are available. These noses are specific to each wire/strand size and
should be ordered accordingly. For use you should consult, the instructions supplied with the nose.
9. Maintenance
Trouble free operation can only be achieved by the operators carefully following these operating
and maintenance instructions. Only a competent fitter should be employed to service this
equipment.
The following section contains number references shown alongside the diagrams -e.g. Main cylinder
(1). These numbers relate to the corresponding components shown in the general assembly
drawings at the end of this manual.
The expressions “unscrew” or “tighten” refer to right handed threads unless otherwise stated.
When gripping components in a vice, fit soft plates over the vice jaws to avoid damaging the jack.
Dirt MUST NOT enter the cylinders, or disconnected hose fittings. Every care must be taken during
assembly and dismantling of the jack to keep all parts CLEAN. Dirt on any part may mix with the oil,
and will score cylinder bores, destroy seals, and affect the correct functioning of the jack and pump
unit valves. New seals, when fitted, should be perfectly clean and smeared with a suitable rubber
lube.
Warning Oil spillage! Some maintenance operations will release oil from the jack. A suitable
container should be made available to catch the oil trapped in the jack. Used oil must be legally
disposed of!
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9.1 Pre-Maintenance Steps
Before commencing with any maintenance operation on the jack the following steps MUST be
followed.
• With the jack and pump connected, ensure the outer tube of the jack is fully retracted (see
Section 8), so that there is no residual pressure within the jack.
• Disconnect the two hoses from the jack and place the protective caps and plugs on the
exposed couplers and fittings.
9.2 Servicing the Lock-Off Cylinder
The lock-off cylinder should be completely dismantled, inspected for wear/damage and cleaned
regularly to ensure proper operation.
9.3 Removal of Lock-Off Cylinder
• Grip the jack by the main cylinder (1) in a shielded vice.

• Grip the flats on the lock-off cylinder (3), do not use the holes in the stressing nose (22).
• Unscrew and withdraw the lock-off cylinder assembly from the lock-off tube (2) taking care
not to damage the seals.
Seals
Stressing Nose (22)
Lock-off Tube (2)
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9.4 Cleaning the Lock-Off Cylinder
• Loosen 2x set screws (54) and holding the lock-off cylinder (3), withdraw the grip release cap
(5). Remove all dirt from behind lock-off piston (4).
Set Screw (54)
Grip Release Cap (5)
Lock-off Piston (4)
• To re-assemble, replace the grip release cap (5). Locate and tighten 2x set screws (54) into
previous position.
9.5 Re-fitting the Lock-Off Cylinder
• Grip the jack by the main cylinder (1) in a shielded vice.

• Apply a fine layer of rubber lube to the two exposed seals on the lock-off cylinder (3).
• Insert the lock-off cylinder (3) into the lock-off tube (2), taking care not to damage the seals
on the internal threads.
• Tighten the lock-off cylinder into the lock-off tube (2) ensuring the mating faces are in
contact.
10. Dismantling and Assembly
Before commencing with any major dismantling operation, the pre-maintenance steps listed in
Sections 11 and 11.1 must be followed.
10.1 Dismantling the Lock-Off Cylinder
• Remove the stressing nose as described in Section 4.2.
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• Remove the lock-off cylinder as described in Section 9.3

• Withdraw the lock-off spring (20) from the lock-off cylinder (3) and push out the lock-off
piston (4) complete with single acting seal (47).
• Slacken 2x set screws (54) and remove the grip release cap (5).
Set Screw (54) Grip Release Cap (5)
Single Acting Seal (47)
Lock-off Piston (4)

and single acting seal
Lock-off Spring (20)
Stressing Nose (22)
• From the outside of the lock-off cylinder (3) remove both back-up rings (41), along with both
o-rings (40).
• Remove the back-up ring (37) and o-ring (32) from inside the lock-off cylinder (3).
O-ring (32
Back-up Ring (37)
O-ring (40)
Back-up Ring (41)
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• Remove single acting seal (47) from lock-off piston (4).
Lock-off Piston (4)
10.1.1 Re-Assembling the Lock-Off Cylinder
• Slide single acting seal (47) onto the rear of the lock-off cylinder (4).
• Insert back-up ring (37) and o-ring (32) into the inner bore of lock-off cylinder (3) in the
order shown in Section 10.1.
• Insert 2x back-up rings (41) and 2x o-rings (40) onto the outer bore of lock-off cylinder (3) in
the order shown in Section 10.1.
• Push grip release cap (5) into the lock-off cylinder (3).
• Locate and tighten 2x set screws (54) into position.
• Insert the lock-off piston (4) into the lock-off cylinder (3), using a suitable grease to lubricate
new seals.
• Insert the lock-off spring (20).
• Screw stressing nose (22) on to lock-off cylinder (3) making sure mating load transfer faces
are in contact.
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10.2 Removal of the Lock-off Tube
• Grip the main cylinder (1) in a shielded vice.

• Remove the front cap cover (18) along with 2x set screws (54) and lock-ring (10).
Front Cap Cover (18)
Lock-Ring (10)
Set Screw (54)
• Unscrew the brass tube nut (29) from under the front cap cover (18).
Tube Nut (29)
• Remove the 4x screws (52) and the lower slot cover (17) from the lock-off tube (2).
• Remove the screw (53) and cylinder slot key (7) from under the lower slot cover (17).
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Cylinder Slot Key (7)
Slot Cover (17)
• The lock-off tube (2) can now be pulled out of the front cap (11).
Front Cap (11)
Lock-off Tube (2)
10.2.1 Re-Fitting of the Lock-off Tube

• Slide the lock-off tube (2) into the front cap (11). Ensure to align the dowel pin and hole
correctly.
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• Tighten the brass tube nut (29) into the front cap (11). Take care not to overtighten or
damage this nut.
• Insert the cylinder slot key (7) into the barrel (6) and secure with screw (53).
• Position the lower slot cover (17) in the lock-off tube (2) and secure with 4x screws (52).
• Tighten the lock-ring (10) onto the front cap (11). Align the threaded holes in the lock-ring
(10) with the marks in the front cap (11) threads and secure with 2x set screws (54)
• Position the front cap cover (18) and secure with 2x screws (51)
10.3 Removal of the Barrel

• Remove the wedge spring tube assembly (19).
• Remove the lock-off tube (2) as described in Section 10.2.
• Remove 2x set screws (54) from the barrel (6).
• The barrel (6) may now be unscrewed from the piston tube (8).
Set Screw (54)
Barrel (6)
Piston Tube (8)
Refitting is simply the reverse of this process, it is very important that the barrel (6) is fully screwed
back on to the piston tube (8) to the original position, so that the set screws (54) are aligned with the
two dimples in the piston tube thread. Follow the steps in Section 10.2 for refitting of the lock-off
tube.
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10.4 Removing the Rear End Cap

• Remove the spring tube retainer (14) and spring tube assembly (19).
Spring Tube Retainer (14)
• Remove 2x set screws (54) from main cylinder (1).

• Unscrew the rear end cap (13) from the main cylinder (1).
Set Screw (54)
Rear End Cap (13)
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10.4.1 Dismantling the Rear End Cap
• Remove the single acting seal (45), wiper (46) and bearing ring (44) from the end cap (13).
Bearing Ring (44)
Rear End Cap (13)
Wiper (46)
10.5 Removing the Piston Tube

• Remove the lock-off cylinder (3), barrel (6) and end cap (13) as described in Section 10.2,
10.3 and 10.4 respectively.
• Pull the retract cylinder (12), piston head (9) and piston tube (8) out through the rear of the
main cylinder (1).
Piston Head (9)
Retract Cylinder (12)
Piston Tube (8)
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10.5.1 Re-Fitting the Piston Tube

• Push the piston head (9), piston tube (8) and retract cylinder (12) into the main cylinder (1),
taking care of the seals on the piston head.
• Refit the barrel (6), lock-off cylinder (3) and end cap (13) as described in Section 10.2, 10.3
and 10.4 respectively.
10.5.2 Dismantling the Piston Tube and Piston Head
• Remove the piston tube (8) as described in Section 10.5.

• Remove the retract cylinder (12) from the piston tube (8) as described in Section 10.6.
• Unscrew the piston head (9) from the piston tube.
Piston Tube (8) Piston Head (9)
• Remove the 2x bearing rings (36) and double acting seal (35) from the piston head (9).
Double Acting Seal (35)
Bearing Ring (36)
Bearing Ring (36)
• Remove the 2x back-up rings (39) and o-ring (38) from the piston tube (8). Only remove
and replace the rings over the non-threaded portion of the piston tube.
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Piston Tube (8)

Back-up Ring (39)
O-ring (38)
Reassembling the piston and piston tube is simply the reverse of this process.
10.6 Removing the Retract Cylinder
• Remove the piston tube (8) as described in Section 10.5.

• Grip the piston tube (8) in a shielded vice.
• Remove 2x set screws (54) from retract cylinder (12)
• Unscrew the retract cylinder (12) off the piston tube (8).
Retract Cylinder (12)
Set Screw (54)
Reassembly of the retract cylinder into the main cylinder is simply the reverse of this process.
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10.6.1 Dismantling the Retract Cylinder
• Remove the o-ring (38) and back-up ring (39) from the front of the retract cylinder (12)
Back-up Ring (39)
O-ring (38)
39)) Retract Cylinder (12)
11. Post-Maintenance Safety and Advice
• After any maintenance procedure which involves removing the barrel, it is vital that the
barrel is fully screwed back on to the piston tube to the original position, so that the set
screws (54) are aligned with the two dimples in the piston tube thread (see Section 10.3)
• Always use clean oil. If the oil becomes cloudy it should be changed immediately,
contaminated oil can damage the jack seals and if water is present causes corrosion.
12. Recommended Spares
• One tin of CCL release agent.

• One complete set of seals.
o 90kN Jack: Part no. 109171
• It is recommended to have at least three sets of wedges and two sets of corresponding O-
rings for each particular size of wire/strand to be stressed.
12.1 Ordering Spares
For individual spares, always specify the reference number, description and part number which can
be obtained from the enclosed general assembly drawing, along with the jack serial number (stamped
on the rear-end cap (18) of the jack.
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90kN Jack Manual

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90kN Jack Manual

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CCL EQUIPMENT MANUAL Stressomatic MKII 90kN Jack

CCL STRESSOMATIC MKII 90kN JACK

CCL Stressomatic MKII 90kN Jack

CCL Stressing Systems Ltd

CCL Stressing Systems Ltd

CCL products have been providing market leading

The current CCL product range reflects over 40

Original CCL Equipment

Original CCL equipment is only manufactured by CCL in

CCL stressing equipment is widely accepted as the world

The CCL range of stressing equipment is designed

10.3 Removal of the Barrel ............................................................................................................ 30

1.1 Product Description

This manual covers the following CCL products:-

• 109090 90kN 40cm/15.7in stroke jack designed for stressing tendons of

1.2 Ancillary Equipment Requirements

To operate the jack you will require the following equipment;

CCL Hydraulic hoses* (or equivalent specification see Section 3.5)

2.1 Main components of the jack

Rear Handle Hose Connectors

Rear End Cap

3.1 90kN Jack Specification

SI Units SI Imperial Units Imperial

SI (mm) Imperial (in)

3.2 Jack/Pump Cycle Times

3.3 Stressing Nose Codes

3.4 Jack Wedge Codes

3.5 Hose Specification

used with CCL equipment. If in doubt contact CCL.

Nominal Bore (A) 3/8in

4.1 Checking the Stressing Nose

4.2 Removing the Stressing Nose

Stressing Nose (22)

Main Cylinder (1)

Lock-off Tube (2)

Lock-off Cylinder (3)

Lock-off Spring (20)

Lock-off Piston (4)

4.3 Checking the Internal Jack Wedges

4.4 Inserting the Internal Jack Wedges

4.5 Wedge Inspection

Visually Inspect threads

An example of good sharp wedge teeth

The deformation seen on this wedge was caused by the strand

Visually inspect for corrosion

Cleaning the wedges as described in Section 5.1 will normally

Visually check for contamination

Clean Teeth Grease/Oil Dirt/Dust Concrete

4.6 Wedge Storage

4.7 Barrel Inspection

5.1 Grip Cleaning Methods

CCL supply a variety of cleaning brushes to suit the range of

The contaminated grip components are placed in the tank

The Wetblast machine uses a water/glass media slurry to remove

Wedges before cleaning Wedges after cleaning

5.2 Wedge Lubrication

Calibration of the jack to the corresponding pump pressure

7. General Precautions and Safety

7.1 Overloading or Improper Use

• Overloading or improper use could lead to FATAL injury.

7.2 Hose Inspection and Maintenance

o Ensure that the hose is free from

o Avoid twisting, knotting or trapping

o Avoid handling the hose