JASH ENGINEERING LIMITED

31, SECTOR ‘C’, INDUSTRIAL AREA, SANWER ROAD,

INDORE 452 015 (M.P.) INDIA
PH: 0091-731-4232900, 2720143
FAX : 0091-731-2720499
E-mail : info@jashindia.com
Website : www.jashindia.com

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

FOR
FLANGE BACK FRAME
‘JASH’ S.S. SLUICE / SLIDE GATES
 INSTALLATION, OPERATION AND MAINTENANCE
MANUAL FOR FLANGE BACK FRAME
‘JASH’ S.S. SLUICE / SLIDE GATES

INDEX

SR. DESCRIPTION PAGE NOS.

NO.

1. INTRODUCTION, UNLOADING AND UNPACKING, HANDLING AND P1 – P4

STORAGE.

2. INSTALLATION PROCEDURE FOR WALL MOUNTING / WALL P5 – P12

THIMBLE MOUNTING GATES.

3. FIXING OF LIFTING RODS/SPINDLES/STEMS, COUPLINGS, GUIDE P13 – P21

BRACKETS AND MANUAL / ELECTRIC GATE ACTUATING
MECHANISM.

4. INITIAL SETTING OF TRANSPARENT PIPEHOOD TYPE GATE P22 – P23

OPENING INDICATOR FOR RISING SPINDLE GATES.

5. FIELD ADJUSTMENTS P24 – P29

6. INITIAL OPERATION OF GATE AFTER COMPLETION OF P30 –P31

INSTALLATION & MAINTENANCE INSTRUCTIONS

7. DO’S AND DON’TS P32

8. TROUBLE SHOOTING P33 – P37

 INSTRUCTION MANUAL FOR JASH STAINLESS STEEL SLUICE GATES

INTRODUCTION:

This manual describes recommended methods of handling and storage, installation, initial operation,
precautions for maintenance and safety of JASH wall / wall thimble mounted manually or
electrically operated Stainless Steel Sluice Gates.

During manufacture and assembly, great care is taken to ensure (joints) flatness of mating seat
facings on the gate frame and shutter in gate fully closed position. Unless the gate is carefully
installed free from distortion, maintaining (joints) flatness of mating seat facings on the gate frame
and shutter as ensured at factory, the gate will leak excessively.

Sluice gates are custom made equipment, comprising of many parts, components and accessories
viz. Gate assembly: comprising of frame, shutter, side and top - bottom wedges etc, Wall thimble
and Lifting mechanism: comprising of operating headstock, lifting rod/spindle/stem, coupling, stem
guide bracket, etc. Being custom equipment made to order on an individual basis, complete inter-
changeability of all parts is not possible and hence replacements and fitments, if necessary involve
substantial time and delays. It is, therefore, essential that the equipment is carefully handled during
transit, unloading, storage and installation to avoid damage and it should be ensured that no pilferage
of components take place. All components are tagged to identify their respective gate as per the gate
tag number / serial number etc. inspected and certified complete at our factory before packing and
shipment.

This manual furnishes information and procedures only as a recommendation for the proper
handling, storage, installation of JASH Wall mounting / Wall thimble mounting Stainless Steel
Sluice Gates. Technical details, data and sketches given in this manual are of a general nature and
may vary from the exact equipment supplied due to project specific requirements or due to the
constant learning and upgrading. JASH endeavor’s to be the leader in our field and tries to keep our
products and designs the best available.

JASH assumes no liability expressed or implied for the interpretation of this instruction manual or
the faulty handling, storage, installation or commissioning of the gates supplied. Responsibility of
JASH is restricted to manufacturing defects only and does not extend to improper installation,
adjustments and related problems subsequent to manufacturing.

UNLOADING AND UNPACKING:

While taking delivery from the Carriers, before unloading packing cases / material from the vehicle,
check the packing cases for apparent damage from outside during transit. Also check unpacked or
partially packed items, if any, for damage or pilferage during transit. In case of any damage or
shortage, obtain carrier’s certificate at the time of taking delivery and report to the Manufacturer
and the Insurer immediately.

Before commencement of unloading verify the weight of the packing cases / material for proper
selection of lifting equipment. This can be done by checking the weight of packing cases / material
from the packing list. In case this information is not available or in case there is any confusion on
this matter then contact! manufacturer immediately, to know the weight or to clarify the doubts.

P-1
The lifting capacity of slings, chains, tackles, hoist, crane etc to be used for unloading and
subsequent handling should be atleast 50% more than the weight of the heaviest packing case /
material to be handled, and remember any excessive out-reach could cause dangerous problems.

Before commencement of unloading also ensure that a leveled, firm and compacted elevated
platform approximately 300 mm (12”) higher than the surrounding area {refer figure ( b )} is ready
for keeping unloaded packing cases / material. The floor area of this platform should be 2 times the
floor area of all the packing cases / material to be unloaded.

Always sling the cases and heavier parts while unloading. Do not drop the cases and the parts on
floor from a height. Do not lift/lower any case containing gate assembly on to its sides and do not
put it upside down. Refer to instructions shown on the packing case showing where the slings should
be used, which side the material is up and how to store the boxes. Refer figure ( a ) above to
understand how to handle packing cases. DO NOT WALK UNDER RAISED PACKING CRATES!

Open the cases immediately on unloading / receipt and check for any damage or pilferage during
transportation. Take care to see that no parts are damaged while opening the cases. Check the
consignment according to packing list enclosed. Report any shortages: or complaints to the
Manufacturer and the Insurer immediately.

HANDLING AND STORAGE:

The Gate should be carefully handled with proper lifting tackles and slings to avoid injury to
persons, breakage and damage to the gate assembly and its components and other parts and
accessories. During storage the equipment should be placed on wooden planks (not spaced more
than 600 mm (24”) over an even compacted surface so as to keep them off the ground and prevent
bending and distortion. Refer figure ( b ) above.

Ferrous contamination, if any, taking place in our plant during manufacturing is eliminated by
pickling and passivation of all stainless steel items before packing and dispatch. To avoid ferrous
contamination of stainless steel components at site please ensure that no stainless steel items come
in direct contact with chains and handling accessories made of carbon steel, as this results into

P-2
ferrous pickup / contamination and subsequent corrosion on stainless steel items in places which
have come in contact with carbon steel. JASH will not be held responsible for ferrous contamination
of stainless steel items taking place at site due to handling and storage in improper manner.

Stacking of large and heavy gates should be avoided as far as possible. If gates are sent stacked from
the factory then no further material should be stored over this stack after unloading. In case where
storage space is limited for the number of gates involved and if stacking is badly necessary it should
be limited to only four gates and heavy wooden planks of even thickness should be placed in
between the gates to prevent damage to the stacked gates. If gates are sent stacked from the
factory then no further material should be kept over this stack after unloading.

Gate assembly, lifting rod and lifting mechanisms have precisely machined and finished surfaces and
hence should be protected from damage during handling as well as storage.

Main gate assembly: comprises of gate frame fitted with shutter in its guides. This assembly is
factory assembled and tested and hence should not be dismantled or disturbed. The shutter is
locked in position at its top with the help of lock plates / transit stop (painted red) bolted to the
frame. These lock plates prevent the vertical movement of shutter in the frame. Lock plates / transit
stop should not be removed until the gate is installed and is to be initially operated. Refer figure ( c )
above to understand location of transit stop / lock plate.

Shutter should never be taken out from the frame during handling, storage or installation.
Adjustment of wedge block bolts, when provided should not be disturbed. Care should be taken to
avoid damage to the wedges and wedge adjustment bolts while slinging and handling.

Utmost care should be taken to avoid bending of lifting rods (spindle) while handling. The threaded
portion of a spindle is applied with grease and is wrapped with thin polyethylene sheet and Hessian
cloth wrapped and tied over it. The threads should be checked for any damage during transit. They
should remain greased and should be kept wrapped up as described above until the spindle is needed
for installation.

P-3
The spindle of self-contained / closed top frame gates {refer figure ( m ) to understand what is a self
contained / closed top frame gate} are sent assembled on to the gate assembly.

Spindles of gates which are not self-contained type / open top frame gates {refer figure ( o ) to
understand what is a non self- contained / open top frame gate} are sent separately. Whether a gate is
self-contained / closed top frame or not self-contained / open top frame can be verified from the
respective GA drawing.

For spindles of open top frame gates ensure the following:

• Ample care should be taken to protect the threading on lifting rods for the ends to be connected
with couplings, if any.
• Rod coupling, when supplied are threaded and pinned on the end of lifting rod and are ready to
be fitted with the threaded end of other rod to be coupled. Ensure that the pins on couplings do
not get loosened and lost.
• Stop Nut is kept threaded on to the spindle threads and is kept fixed with a set screw. Ensure that
it does not get loosened and lost.
• Spindles or lifting rods should be supported over their entire length with a view to prevent
bending. They should be carefully stored on even surfaces off the ground and in a clean and dry
area.

During storage care should be taken to cover the equipment to protect seat facings, seals and other
machined surfaces from scratches, dents, rusting etc. and from other foreign matter. The cover
should be of material, which is resistant to water and should cover the entire case from top to
bottom.

Packing cases containing operating mechanism (manual operating headstocks / electric actuators /
pneumatic actuators etc) and small parts and anchor bolts / fasteners should be preferably kept in
store room to prevent damage from environmental causes like dirt, dust, sunlight and rain and also
with a view to prevent chances of pilferage.

In case of any doubt pertaining to handling/storage of supplied material refer to the manufacturer.

WARNING:

Follow appropriate safety measures/laws and working conditions as applicable for your
project or as applicable in your Country while unloading, handling, installation and
commissioning of this equipment. Take due care to avoid ferrous contamination on stainless
steel items while handling, storage and installation of supplied products.

JASH assumes no liability for accidents or damages taking place during the process of
handling, storage, installation or commissioning of the gates supplied.

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-

P-4
 INSTALLATION PROCEDURE FOR:
WALL MOUNTING / WALL THIMBLE MOUNTING GATES

The supplied stainless-steel gates can be mounted (A) Directly on the face of a wall, or (B)
Mounted on a wall thimble to be grouted in the wall. Please verify from the approved GA drawing
whether mounting (A) or (B) is provided. After ascertaining this, follow the installation procedure
(A) or (B) as given hereunder.

Before commencement of installation, check the civil conditions site for correctness of all
dimensions as shown in the approved GA Drawing / Civil Block out drawing furnished by JASH for
the gate being installed. Specially check whether the center line of the gate opening and invert of
platform is as per drawing, check whether the size of the opening for wall mounting gate or block
out where the wall thimble is to be mounted is correct, check whether the groove provided in front of
gate for flush bottom closing gates is of correct size and depth.

Also specifically check for the correct location of the hole provided in the floor platform for passage
of the spindle.

Proceed only if all the dimensions are CORRECT or else first rectify the civil mistakes so that there
are no subsequent problems.

(A) INSTALLATION PROCEDURE FOR WALL MOUNTING GATES:

These gates are mounted on the face of a wall using anchor fasteners, and for fixing anchor
fasteners, holes have to be drilled in the wall. There remains a possibility that reinforcement steel
bars placed in wall may come in the way of these holes. When this happens then it may result into
increased drilling time and cost as well as possible weakening of structure. To avoid this, location of
anchor fasteners should be ascertained from the gate manufacturer before casting of wall and
thereafter reinforcement bars so positioned, that they do not foul/conflict with holes to be drilled
subsequently.

Procedure to be followed if the gate is to be directly mounted on the face of wall using anchor
fasteners (chemical or mechanical).

P-5
1. Before the wall is cast ensure that location of reinforcement bars is offset from the location of
anchor fasteners. So as to prevent drilling through the reinforcement bars.

2. After the wall is cast, check the flatness of the gate mounting area on the wall. Refer figure (d)
above to understand what is the gate mounting area.

3. If you intend to mount the gate directly on the face of the wall with a rubber gasket in between as
shown in the figure (f) below then you have to ensure that the flatness of the gate mounting area
on the wall is within 2 mm (1/16”). If this is not ensured and the gate is mounted on uneven face
of the wall then the gate frame will get distorted leading to excess leakage and excessive
operation torque and JASH would not be responsible for problem arising thereof.

4. If you are not able to ensure flatness of gate mounting area on the wall within 2 mm then mount
the gate frame away from the wall using the shims and after the gate is properly aligned fill
secondary grout between the wall and the gate frame. Refer figure (h) below to understand how
this is done.

5. Before the gate is installed, the anchor fasteners should be embedded in masonry. Anchor
fasteners holes in gate frame are drilled accurately. It is difficult to embed anchor bolts in
concrete to exact spacing of anchor bolt holes on the gate frame without using templates. It is,
therefore, recommended that a suitable wooden or metal template, rigid and well braced, be
made to locate all the anchor fasteners around the aperture of water way opening. Also mark out
the centre lines of water way opening on the template. This is essential to ensure that the anchor
fasteners are fixed in such a way that the gate assembly remains in proper plumb after it is
mounted on the anchor fasteners.

NOTE- The hole drilling on the gate frame for anchor fasteners is done using a template in the
plant. A common template is used for drilling holes on all the gates of the same size having same
drilling pattern in a specific order. Hence a template produced at site by carefully transferring
and marking holes location upon it through the holes drilled on any gate of same size can be used
for all such gates having same size and same drilling pattern. Refer figure ( e ) below to
understand how a steel template can be made for ease in hole drilling on wall.

In case the drilling template is supplied by JASH then there exists a possibility that it may have
got skewed / twisted / damaged during transportation to site or while handling / storage at site.
So before using this template verify correctness of template with respect to drawing and actual
frame of gate.

P-6
6. After verifying the correctness of the template, offer the template up to the installation position
and carefully locate it after ensuring that template is properly positioned vertically using plumb
line and centre line marks.

7. Drill pre holes in the concrete as reference for further drilling using the template. After all the pre
holes are made, the template can be removed, and final holes of the correct size (suiting the
diameter of the anchor fastener) should be made to the depth as shown on the GA drawing.
While drilling the holes in the concrete ensure that the holes are square to the vertical plumb and
that they are not over size and oblong. Please refer to the instruction given by the mechanical /
chemical anchor fastener manufacturer for the size of the hole to be drilled for the given size of
anchor fastener.

8. Secure the anchor fasteners in the wall following the procedure recommended by the anchor
fastener manufacturer.

9. Once the anchor fasteners are put in the wall then the site is ready for mounting of gate.
Depending upon the manner in which you intend to mount the gate follow the procedure ( A ) or
( B ) as given below

( A ) Procedure to be followed if the gate is to be mounted on the wall using rubber gasket
between wall and frame

i) A soft rubber gasket is provided separately for mounting between the wall and back flange of
frame around the opening in the wall aperture. This gasket should be stuck in position at the
back of frame using silicon adhesive. Refer to figure ( f ) above showing cross section of frame
at wall aperture and use of rubber gasket.

ii) Lift the gate assembly with the rubber gasket pasted on its back and position it in place over the
protruding anchor bolts.

iii) Tighten carefully the anchor bolt nuts without straining the gate frame. Check the plumb in all
directions.
P-7
 iv) While tightening the anchor bolt nuts of the frame guide extension, ensure that packers of
sufficient thickness are placed between the wall and back portion of extension guides to prevent
straining of frame guide extension. Refer to figure ( g ) above showing cross section at frame
extension guides.

v) Check the gap between mating sealing faces of shutter and frame for non-acceptance of 0.1 mm.
thick feeler gauge. If the gap is more than 0.1 mm, insert packers or wedges as and where
necessary between the wall and the back of gate frame until the gap between mating seat facings
does not accept 0.1 mm thick feeler gauge. Insert packers or wedges only where the gap is more
than 0.1 mm and the packer thickness should be sufficient enough just to close the gap. Over
packing should be avoided to prevent high contact areas.

With the above procedure the installation of gate assembly on a wall is complete.

( B ) Procedure to be followed if the gate is to be mounted on the wall using shims and rubber
gasket between wall and frame

i) To avoid distortion of gate frame due to uneven face of wall, insert 20-25 mm thick (3/4”-1”)
(or of thickness as required to locate the gate flange at a vertical plane about 25 mm (1”) away
from concrete) steel packing pieces (shims) between the back face of the gate frame and the
concrete wall, in sufficient number, nearer to the locating foundation bolt positions so that the
gate can be firmly tightened against the shims without distortion. Refer figure ( h ) above to
understand how the shims are to be used to locate gate flange in a vertical plane away from
face of wall.

ii) Check the gap between mating sealing faces of shutter and frame for non-acceptance of 0.1
mm. thick feeler gauge. If the gap is more than 0.1 mm, insert packers or wedges as and where
necessary between the wall and the back of gate frame until the gap between mating seat
facings does not accept 0.1 mm thick feeler gauge. Insert packers or wedges only where the
gap is more than 0.1 mm and sufficient enough just to close the gap. Over packing should be
avoided to prevent high contact areas.

P-8
iii) Carry out the gap check carefully because the sealing characteristic of the installed gate
depends upon achieving this setting of keeping the gap minimum and uniform throughout the
sealing perimeter of the gate.

iv) Shutter up around frame without disturbing the setting between the mating sealing faces.

v) Carefully pour high strength quick setting fluid grout in the gaps between the wall and gate
frame ensuring that the gap is totally filled. Allow grout to cure thoroughly, allowing at least
six clear days for proper curing. Make sure NO grout seeps into gate seals, horizontal or
vertical, inside and out. Clean off any excess grout material.

vi) Tighten carefully the anchor bolt nuts without straining the gate frame. Check the plumb in all
directions.

vii) While tightening the anchor bolt nuts of the frame guide extension ensure that packers of
sufficient thickness are placed between the wall and back portion of extension guides to
prevent straining of frame guide extension. Refer to figure ( f ) showing cross section at frame
extension guides.

With the above procedure the installation of gate assembly on wall is complete.

(B) INSTALLATION PROCEDURE FOR WALL THIMBLE MOUNTING GATES :

These gates are mounted on a wall thimble embedded in the wall. For embedment of wall thimble in
the wall a block-out should be provided while casting the wall. The dimensions of this block-out
should be ascertained from the gate manufacturer before the wall is cast. Generally the block-out
size can be kept as width of gate opening + 600 mm (+ 24”) {(W+600 mm) / (W+24”)} , height of
gate opening + 600 mm (+ 24”) {(H+600 mm) / (H+24”)}and the depth of block-out can be kept
equal to the depth of wall / 350 mm (14”).

(i) INSTALLATION OF WALL THIMBLE :

1. Ensure that the inner face of the block out is roughed out for proper adhesion of the second stage
grout. Also expose some reinforcement bars of the first stage concrete wall for bracing of the
thimble.

2. Bring the wall thimble to the location of installation only when the civil site has been checked
for correctness and is fully ready for installation of thimble. Do not un-wrap the plastic foil
wrapped on the thimble until found necessary. If possible remove this only after the installation
at location and before commencement of grouting. The tapped holes on the front flange of wall
thimble are provided with plastic caps to prevent ingress of dirt, dust etc. Do not remove these
until necessary.

P-9
3. The front flange of wall thimble is marked with vertical and horizontal centre lines. Both the
centre lines are further extended to the outer edges of wall thimble flange. Word `Top’ is punch
marked on the flange and is to be kept at the top while setting into position, with its vertical
centre line in plumb. Refer figure ( i ) to understand how a thimble looks like.

4. Brace the thimble internally with vertical and horizontal bracings, as shown in figure ( j ) above,
to avoid distortion of thimble under weight of the concrete. While bracing the wall thimble
internally, take care to avoid distortion of wall thimble internally and take care to avoid
distortion of wall thimble due to bracing itself. If the wall thimble is distorted either due to
improper internal bracing or due to weight of the concrete, the positions of the studs on the wall
thimble will get mis-aligned with respect to holes drilled on gate flange.

P-10
5. Carefully set the thimble in position within the block out after ensuring that it is properly
positioned vertically using plumb line and centre line marks. Ensure that the alignment of the
horizontal center line is as per level shown in approved GA drawing. Recheck the vertical
alignment of the thimble flange face in relation to the plumb at extreme right end, center / middle
and extreme left end.

6. Brace/Tie the thimble using binding wires between the exposed reinforcement bars of first stage
concrete wall and nelson studs provided on thimble. Provide additional packings / bracings / ties
to support the thimble firmly and evenly around the perimeter so as to ensure that the thimble is
secure and will not move while carrying out second stage grouting.

7. Cover up the tapped holes from the back to ensure that grout does not enter in the tapped holes.
If possible, it would be preferable to additionally block these tapped holes with cotton rags to
prevent concrete from entering the holes.

8. Use formwork to close the gap between the wall and the thimble flange. If required bolt the
thimbles to wooden form by employing studs on thimble flange.

9. Support the forms properly with suitable stiffeners and braces to further avoid displacement of
thimble and distortion of its flange. Exercise this caution to prevent leakage from the gate joint
with a distorted flange later.

10. Pour the concrete. Remove the forms after the concrete is hardened. Thoroughly clean the front
surface of thimble flange from any concrete or dirt. Clean the concrete, if any, from the tapped
holes.

(ii) INSTALLATION OF GATE ON WALL THIMBLE:

1. Remove the plastic caps from the front of the tapped holes and clean the threads. Thoroughly
clean the face of wall thimble.

2. Apply grease on the threads and insert studs in the tapped holes.

P-11
3. Place the sheet rubber gasket in position on the face of wall thimble. Refer figure ( k ) above. If
the gasket is not in one piece, the male and female V ends of gasket pieces should be properly
aligned and matched. Thoroughly clean the mounting flange of Sluice Gate. Take proper care to
prevent any damage to the surfaces while installing.

4. Put the gate assembly (comprising of gate frame and shutter) in position carefully inserting the
studs in the gate flange. Avoid damage to the stud threads in the process. Put the nuts on studs
and tighten carefully. Carefully tighten each nut attending to opposing nuts in turn, as shown in
figure ( l ) above. Below given procedures may be followed for tightening :

• First tighten the top most nut nearest to the vertical centre line. Then tighten the diametrically
opposite bottom most nut. Then tighten the nut located immediately above the horizontal centre
line and follow with tightening the diametrically opposite nut.

• Follow similar procedure in respect of other nuts. Tightening of all the nuts should be uniform
and even, with equal torque to avoid distortion of gate flange.

• Do not tighten one nut under full torque at any point in the sequence until all nuts began to
compress the gasket.

• Maximum torque to be applied to all bolts / studs / nuts of M12, M16, M20 and M24 sizes is 47,
102, 136 and 260 N-m respectively.

NOTE: In case of those installations where rubber gasket is not to be used, apply a thin coat of
mastic or fibrated asphalt on the front face of thimble.

With the above procedure the installation of gate assembly on wall thimble is complete.

WARNING:

Each gate assembly is tested for non-acceptance of 0.1 mm thick feeler gauge between mating
sealing faces of gate and gate frames before dispatch from plant. Gates are dispatched only
when they meet the seal clearance criteria specified in the applicable standard/specification
and accepted by JASH during the finalization of order. All Gates are tested for leakage
performance before dispatch from plant at actual water head applicable on it, but from
unseating side. Gates are dispatched only when they meet the leakage criterion specified in
applicable standard / specification and as accepted by JASH during the finalization of order.
Improper installation may result into deterioration in gate leakage performance for which
JASH cannot be held responsible.

Hence JASH assumes no liability for leakage performance of gates if the entire installation has
not been done under the supervision of a competent Engineer following JASH instructions.
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P-12
 INSTALLATION OF LIFTING RODS /STEMS /SPINDLES
& MANUAL / ELECTRIC GATE OPERATING MECHANISM

The supplied Stainless Steel Gates can be provided with a manual operating arrangement or an
electric operating arrangement. Manual or electrically operated gates can be Self-contained type /
closed top frame gate or Non self-contained type / open top frame. Please verify from the approved
GA drawing whether these gates are manual or electric operated and whether these are self-
contained or non self-contained and then accordingly follow the installation procedure (A) or (B)
as given hereunder.

(A) MANUAL GATE OPERATING MECHANISM / HEADSTOCK

(i) FOR SELF-CONTAINED TYPE GATES:

In case of self-contained type gates {refer figure ( m ) below}, the stem, yoke, gate operating
mechanism / headstock and stop nut are generally supplied in factory assembled condition alongwith
gate assembly. Pipe hood, if provided, is packed separately and not supplied in factory assembled
condition.

Gates provided with geared headstock, only the crank handle may be required to be secured on the
operating shaft of the gear box to enable operation of the gate.

P-13
 Gates provided with un-geared headstocks only, the handwheel may be required to be fitted to
enable operation of the gate. For this, following procedure is used:

1. Unscrew the set screw provided on the stop nut and remove the stop nut from the spindle top.

2. Insert the handwheel and mount it on top of the stem nut. Tighten the set screw provided on
handwheel boss on to the stem nut to secure the handwheel on stem nut.

3. Mount the stop nut on the spindle and lower it in a way that when the gate is in fully closed
position the bottom of the stop nut remains just one millimeter above the top of spindle nut
of headstock. Refer figure ( n ). Once the stop nut is set in its position secure it there with the
help of setscrew provided in the stop nut.

The purpose of providing stop nut is to prevent the chances of over closing of gate i.e. to prevent
the operator from applying excess torque for gate closing even after the gate is fully closed.

When such excess torque is applied, either the spindle/stem will get bent or the headstock will be
uprooted from the yoke on which it is mounted, or the yoke may get uprooted from the frame on
which it is mounted or the shutter may get damaged. To avoid occurrence of any of these
problems, it is very critical that stop nut is secured at the correct location as stated above.

(ii) FOR GATES WHICH ARE NON SELF-CONTAINED TYPE:

In case of gates which are not self-contained type {refer figure ( o ) below}, the stem, stop nut,
coupling and headstock are supplied separate from gate assembly.

P-14
Following procedure should be adapted for fixing of stem / spindle, coupling, guide brackets,
headstock and stop nut:
1. Each lifting rod / stem for a particular gate is marked for identification. Ensure that correct stem
is employed for a particular gate. Lifting rods or stems are supplied with stop nut and couplings,
if any, attached. The ends of extensions stem to be connected with respective couplings are
punched marked to facilitate identification. Verify all these.

2. The threaded portion of the lifting rod should be checked for damage, if any. It is desirable to
carry out necessary rectification before proceeding with installation.

3. The lifting rod/stem is required to be connected with the shutter either (a) with the help of a pin
housed in two lugs cast integral with the shutter, or (b) with the help of a stem block or thrust nut
to be housed in a pocket with the shutter, as the case may be, in case of each individual gate.
Check which of the above two arrangements is provided in the gate in question.

In case of arrangement as (a) {refer figure ( p ) above}, the pin is supplied duly inserted in two
lugs of the shutter. The pin is kept in position with the help of a nut at its other end and is
supplied with a spilt pin to check the nut from opening out. In case of this arrangement the
bottom end of the stem has a fixed horizontal boss. Remove the pin from the lugs of the shutter,
put the stem end with horizontal boss in position, insert the pin through the lugs and horizontal
boss hole in stem end and secure the pin in position by tightening the nut at its end. Re-insert the
split pin its hole on the pin and open out its end. By doing this the shutter is connected to the
spindle.

In case of arrangement as (b) {refer figure ( p ) above}, the stem block/thrust nut is supplied
either duly threaded on the stem end with set screw in position, or is supplied duly housed in its
pocket on the shutter. Remove the stem block from the stem end, if it is there, and put it in its
pocket in the shutter. Lower the stem end to be connected through the holes in the upper ribbing
and thread into the stem block/thrust nut. Ensure that the stem end remains flush with the bottom
end of nut. Put the set screw in position for preventing the rotation of stem in the stem
block/thrust nut. By doing this the shutter is connected to the spindle.

P-15

4. The stem should be properly supported as it passes through the stem guides in proper sequence.
Wherever required, extension pieces of stem should be connected with the threaded couplings.
 After the stem end is connected with the coupling & pin should be inserted through the matching
holes on the coupling as well as the stem.

5. Adjust the stem guide brackets to maintain the stem in a vertical plumb position. Keep the stem
guide a little loose on the guide bracket. It should be firmly tightened only after the headstock is
mounted.

6. Each headstock for a particular gate is marked for identification. Ensure that correct headstock is
employed for a particular gate.

7. Insert the threaded end of the stem into the headstock and ensure that minimum 20” (500 mm)
length of threaded stem is projecting from the top of the headstock.

8. Place the headstock with the stem at the installation location on the platform. After the headstock
is placed in position lower the stem up to the stem coming from the gate by rotating the
handwheel / crank handle.

9. Engage the stem coming from the headstock to the coupling mounted on the stem coming from
the gate. After the stem end is connected with the coupling, pin (bolts) should be inserted
through the matching holes on the coupling as well as the stem.

10. Put suitable shims between the platform top and the headstock base keeping a gap of about ¾” to
1” (20/25 mm). Adjust the shims to maintain the headstock pillar in plumb. Check the alignment
of the stem with a plumb level. Grout the gap between the platform and headstock base and also
grout the pockets of anchor bolts. Remove the shims after hardening of grout. Tighten the nuts
on anchor bolts to secure the headstock firmly on the platform.

11. Turn the handwheel / crank handle slightly in the direction of opening the gate, without actually
opening the gate, merely for the purpose of making the stem taut and straight.

12. Finally align the stem guide maintaining uniform clearance all round the stem and the bore of
stem guide and firmly tighten the stem guide on the guide bracket.

13. Clean the stem thoroughly and lubricate with heavy-duty grease.

14. Locate the stop nut on to the top of stem in such a way that when the gate is in fully closed
position the bottom of the stop nut remains just one millimeter above the top of spindle nut
of headstock. Refer figure ( n ) Set it there with the help of set screw.

The purpose of providing stop nut is to prevent the chances of over closing of gate i.e. to prevent
the operator from applying excess torque for gate closing even after the gate is fully closed.
When such excess torque is applied, either the spindle/stem will get bent or the headstock will be
uprooted from its operating platform or the shutter may get damaged. To avoid occurrence of any
of these problems, it is very critical that stop nut is secured at the correct location as stated
above.

P-16

15. In case the optional pipe hood (galvanized / transparent plastic) is also supplied with the
headstock upon specific request, it should be fitted on the top of headstock after setting of the
stop nut, keeping the stem end with stop nut inside the pipe hood.
 By following the above procedure the fixing of lifting rods with the manual operating mechanism
is complete.

(B) ELECTRIC GATE OPERATING MECHANISM

(i) FOR SELF-CONTAINED TYPE GATES:

In case of self-contained type gates, the stem, yoke, actuator mounting base plate / adaptor plate
and stop nut are generally supplied in factory assembled condition alongwith gate assembly. The
actuator is supplied separately packed and hence at site only the actuator may have to be
mounted on the actuator mounting base plate / adaptor plate. Pipe hood, if provided, is also
packed separately and not supplied in factory assembled condition. Refer figure ( q ) below.

For assembling the threaded spindle with the actuator follow the procedure as explained below:

1. Unscrew the set screw provided on the stop nut and remove the stop nut from the spindle top.

2. Each actuator for a particular gate is marked for identification. Refer to the gate size / tag number
marked on the actuator to ensure that correct actuator is employed for a particular gate.
P-17

3. Then lower the actuator on to the pre-installed threaded spindle and engage the drive nut to the
threaded spindle by rotating the actuator.
4. Rotate the actuator until it reaches down to the actuator mounting base plate / adaptor plate and
bolt up with adaptor plate.

5. Turn the hand wheel of the actuator slightly in the direction of opening the gate, without actually
opening the gate, merely for the purpose of making the stem taut and straight.

6. Finally check the alignment of the stem with a plumb level or line and after alignment operate
the gate manually. If the gate operation is smooth then tighten the bolts securing the actuator on
to adaptor plate.

7. Mount the stop nut on the spindle and lower it in a way that when the gate is in fully closed
position the bottom of the stop nut remains just one millimeter above the top of drive nut of
actuator. Refer to figure ( n ) once the stop nut is set in its position secure it there with the help
of set screw provided in the stop nut.

The purpose of providing stop nut is to prevent the chances of over closing of gate i.e. to prevent
the operator from applying excess torque for gate closing (while in manual operation) even after
the gate is fully closed. When such excess torque is applied, either the spindle/stem will get bent
or the adaptor plate / actuator will be uprooted from the yoke on which it is mounted, or the yoke
may get uprooted from the frame on which it is mounted or the shutter may get damaged. To
avoid occurrence of any of these problems, it is very critical that stop nut is secured at the
correct location as stated above.

8. Clean the stem thoroughly and lubricate with heavy duty grease.

9. Set the end of travel limit switches and wire up the actuator for operation. Set the torque switch
at 80% - 90% of the torque range. Refer to the operating and installation manual of the
actuator manufacturer to understand how to do this.

10. In case a pipe hood (galvanized steel / transparent plastic) is also supplied with the operating
arrangement upon specific request, it should be fitted on the top of the actuator. Galvanized pipe
hood have threads for mounting on to the top of actuator whereas the transparent pipe hood is to
be secured to the sleeve of actuator using adhesive.

By following the above procedure the fixing of lifting rods with the actuator is complete.

(ii) FOR GATES WHICH ARE NOT SELF-CONTAINED TYPE:

In case of gates, which are not self-contained type, the stem, stop nut, coupling, pillar and
actuator are supplied separate from gate assembly. Refer figure ( r ).

Following procedure should be adapted for fixing of stem / spindle, coupling, guide brackets,
pillar, actuator and stop nut:

P-18

Each actuator for a particular gate is marked for identification. Refer to the gate size / tag number
marked on the actuator to ensure that correct actuator is employed for a particular gate.
1. For assembling the threaded spindle with the actuator two alternative methods as explained
below can be followed depending upon which method is more suitable to follow at site.

Method – 1: Assembly by lowering the actuator on to the pre- installed threaded spindle.

Ensure that the complete stem including the threaded spindle is placed in position. Lower the
pillar on to the stem from its top and rest the pillar on the platform. Then lower the actuator on to
the threaded spindle and engage the drive nut to the threaded spindle by rotating the actuator.
Rotate the actuator until it reaches down to the pillar and bolt up with pillar.

Method – 2: Pre-assemble the threaded spindle, pillar and actuator in horizontal condition and
then mount vertically on platform.

Insert the threaded end of the stem into the actuator and ensure that about 20” (500 mm) length
of threaded stem is projecting from the top of the actuator. Mount the actuator along with the
stem on to the pillar in horizontal position. Lift the assembly of stem, pillar and actuator by a
hoisting arrangement and locate the pillar vertically at the installation position.

After the pillar with actuator is placed in vertical position lower the threaded stem up to the stem
coming from the gate by rotating the hand wheel provided on the actuator. See procedure
described in (A) (ii) 1-5 to assemble the stem coming from gate.

Engage the stem coming from the actuator to the coupling mounted on the stem coming from the
gate. After the stem end is connected with the coupling, pin (bolts) should be inserted through
the matching holes on the coupling as well as the stem.

P-19
2. Put suitable shims between the platform top and the headstock base/Actuator pillar keeping a gap
of about ¾” to 1” (20/25 mm). Adjust the shims to maintain the headstock pillar in plumb. Check
the alignment of the stem with a plumb level/line. Grout the gap between the platform and
 headstock base and also grout the pockets of anchor bolts. Remove the shims after hardening of
grout. Tighten the nuts on anchor bolts to secure the headstock firmly on the platform.

3. Turn the hand wheel of the actuator slightly in the direction of opening the gate, without actually
opening the gate, merely for the purpose of making the stem taut and straight.

4. Finally align the stem guide maintaining uniform clearance all round the stem and the bore of
stem guide and firmly tighten the stem guide on the guide bracket.

5. Finally check the alignment of the stem with a plumb level/line and after alignment operates the
gate manually. If the gate operation is smooth then tighten the bolts securing the actuator on to
pillar on platform.

6. Mount the stop nut on the spindle and lower it in a way that when the gate is in fully closed
position the bottom of the stop nut remains just one millimeter above the top of drive nut of
actuator. Refer to figure ( n ) once the stop nut is set in its position secure it there with the help
of set screw provided in the stop nut.

The purpose of providing a stop nut is to prevent the chances of over closing of gate i.e. to
prevent the operator from applying excess torque for gate closing (while in manual operation)
even after the gate is fully closed. When such excess torque is applied, either the spindle/stem
will get bent or the adaptor plate / actuator will be uprooted from the yoke on which it is
mounted, or the yoke may get uprooted from the frame on which it is mounted or the shutter may
get damaged. To avoid occurrence of any of these, it is very critical that stop nut is secured
at the correct location as stated above.

7. Clean the stem thoroughly and lubricate with heavy duty grease.

8. Set the end of travel limit switches and wire up the actuator for operation. Set the torque switch
at 80% - 90% of the torque range. Refer to the operating and installation manual of the
actuator manufacturer to understand how to do this.

9. In case a pipe hood (galvanized steel / transparent plastic) is also supplied with the operating
arrangement upon specific request, it should be fitted on the top of the actuator. Galvanized pipe
hood have threads for mounting on to the top of actuator whereas the transparent pipe hood is to
be secured to the sleeve of actuator using adhesive.

By following the above procedure the fixing of lifting rods with the actuator is complete.

WARNING:

Selection of Operating mechanism ( whether manual or electric) of a gate is done on the basis
of actual head acting on each gate and ensuring that required torque for proper operation of
gate is met by selected operating mechanism. However factors like higher head than specified,
improper installation of gate assembly, stem guide, stem and operating mechanism and
P-20

Improper alignment of all these items may result into higher torque requirement than
envisaged while doing the selection of operating mechanism. This will in turn affect proper and
smooth working of gate for which JASH cannot be held responsible.
Before electrical operation, make sure the phase discrimination is correct , make sure transit
stops are removed. Manually raise the shutter 6” (150mm). Press the close button; if the Door
rises then, the electrical phase is wrong. Change the supply wires, and try again.

Setting actuator limits, torque setting, and any electrical wiring etc. is not the responsibility of
JASH, and is not warranted by JASH.

JASH assumes no liability for performance of gate operating mechanism if the entire
installation has not been done under the supervision of a competent Engineer following JASH
instructions.

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P-21
 INITIAL SETTING OF TRANSPARENT PIPEHOOD
TYPE: GATE OPENING INDICATOR FOR RISING SPINDLE GATES

{Gate travel / opening indicating arrangement is furnished only if specifically asked for by the
buyer and provided it is agreed to furnish the same. In case this arrangement is furnished then
the instruction given below are to be followed.}

Pipe hood, if provided, is packed separately. Transparent Pipe hood type Gate travel / opening
indicating arrangement normally provided is as shown in figure ( s ) below.

In case of un-geared headstocks the pipe hood is fitted on the hub of the handwheel. The indicator
disc is fitted on the adjusting nut, which is mounted on the spindle. The pipe hood is provided with
indication for “Open” and “Close” position. Extent of gate opening is indicated by the position of
indicator disc with reference to the “Open” and “Close” position. Since the pipe hood is mounted on
the hub of the handwheel it would also rotate with the handwheel.

In case of geared headstocks the pipe hood is fitted into a collar on the top of gear housing. The
indicator pointer is fitted on the adjusting nut, which is mounted on the spindle. The pipe hood is
provided with indication for “Open” and “Close” position. Extent of gate opening is indicated by the
position of indicator disc with reference to the “Open” and “Close” position.

P-22
Following steps are to be taken for initial setting of gate opening indicating arrangement: -

a) Set the position of stop nut on spindle in a way that when the gate is in fully closed position the
bottom of stop nut remains just one millimeter above the top of spindle nut / headstock.

b) Set the adjusting indicating nut approximately 1” (25 mm) above the stop nut.

c) Mount the pipe hood in to threaded collar / threaded hub on operating headstock.

d) Observe relative position of indicator disc/pointer which is fitted on adjusting indication nut and
`C’ / “Close” mark on the pipe hood.

e) If it is not in line with the mark of `C’ / “Close” mark on pipe hood then measure the difference.
Dismount the pipe hood and rotate the adjusting indicating nut to raise or lower it suitably by the
difference measured earlier.

f) Fix the position of adjusting indicating nut on spindle with the help of set screw provided for this
purpose.

g) Remount the pipe hood and set it to correspond with “C”/ “Close” mark with indicator disc.

-------------------------------------------------------------------------------------------------------------------------
-

P-23
 FIELD ADJUSTMENTS

(A) PROCEDURE FOR FIELD ADJUSTMENT OF SEALING ARRANGEMENT:

Sealing arrangement is provided to control the water leakage from between the frame and shutter.
Type of sealing arrangement furnished depends upon various factors like size of gate, leakage
requirement, applicable specifications etc.

Sluice Gates are provided with sealing arrangement on the periphery of opening on two vertical
sides, top side and on bottom side. The bottom sealing arrangement can be conventional bottom type
or flush bottom type based on site functional requirement or client requirement.

All the gates are tested for leakage at factory. All the gates assemblies with their sealing arrangement
are properly set at the factory prior to despatch of gates. This setting should not be disturbed at site.
However, sometimes this setting may have to be field adjusted with a view to reduce the extent of
leakage taking place due to distortion of frame while installation and resultant increase in gap
between sealing faces.

The buyer can adapt various methods to conduct field adjustment depending upon the type of sealing
arrangement provided and depending upon type of features provided on the supplied gate.

Generally three types of sealing arrangements are provided in fabricated stainless steel gates as
shown in figure ( t ) and ( u ). Verify type of sealing arrangement provided in the gates of your
order and proceed accordingly.

Firstly check the gap between mating sealing faces of shutter and frame for non-acceptance of 0.1
mm thick feeler gauge as shown in figure ( t ) and ( u ).

P-24
If the gap is more than 0.1 mm then follow procedure as given hereunder:

(i) Adjust the wedges in case the same are provided. The procedure for wedge adjustment is
explained in para B on the next pages.

(ii) If wedges are not provided or if wedges are provided but wedge adjustment cannot achieve the
desired result then gate frame distortion has to be rectified. For this loosen the nuts of the anchor
bolts /studs securing the frame on the wall / wall thimble and then insert packings where
necessary between the wall / wall thimble and the back of gate frame until the gap between
mating seat facings does not accept 0.1 mm thick feeler gauge. Insert packings only where the
gap is more than 0.1 mm and the packing thickness should be sufficient enough just to close the
gap. Over packing should be avoided to prevent high contact areas.

Once again carry out the gap check carefully because the sealing characteristic of the installed gate
depends upon achieving this setting of keeping the gap minimum and uniform throughout the sealing
perimeter of the gate.

P-25
(B) PROCEDURE FOR FIELD ADJUSTMENT OF WEDGES: (If provided)

Provision of wedges is given to reduce the wear of the seal (Rubber / UHMWPE) and to reduce
the torque during opening / closing operation of gate. Wedges are furnished only if specifically
asked for by the buyer and provided it is agreed to furnish the same. In case this arrangement is
furnished then the instruction given below are to be followed for site adjustment required, if any.

Gates are provided with Side, top and bottom wedges depending upon application requirement and
type of sealing offered. Top and bottom wedges are provided only when the gates are subjected to
high unseating heads. However bottom wedges are not provided whenever gates are provided with
Flush bottom closure arrangement.

All the wedges are properly set in the gate assemblies at the factory prior to despatch of gates. This
setting should not be disturbed at site. However, sometimes this setting may have to be field adjusted
with a view to reduce the extent of leakage taking place due to distortion of frame while installation
and resultant increase in gap between sealing faces or due to wear of sealing faces due to continuous
use after few years.

Hence it may be necessary for the wedges to be reset by the Buyer at his end, after the installation of
gates or upon usage.

(i) SETTING OF SIDE WEDGES:

{Provided only in gates having Resilient sealing arrangement as shown in figure ( v ) below }

P-26
The following procedure is recommended for setting of side wedges:

1. Ensure that the gate is fully closed.

2. Slightly loosen the clamping nuts of the adjustable side wedges mounted on frame.

3. Loosen the locknut on the wedge adjusting screws and back out the locknut by a few turns.

4. Move the adjustable wedge down by tightening / pushing down the wedge adjustment screw.
Tighten the wedge adjusting screws sufficiently to ensure that their ends properly bear against
the adjustable wedge.

5. After ensuring that the adjustable wedge is resting on the fixed wedge mounted on shutter,
tighten the clamping nuts of the frame mounted adjustable wedges for keeping the wedges in
place.

6. Tighten / secure the locknuts on the adjustable wedge to lock the movement of adjusting screw.

7. Carry out this procedure for all the side wedges.

(ii) SETTING OF TOP & BOTTOM WEDGES :

{Refer to figure ( w ) below for Top and Bottom wedging arrangement provided in gates having
resilient sealing arrangement.}

{Refer to figure ( x ) below for top wedging arrangement provided in gates having UHMWPE
sealing arrangement and subjected to high unseating head.}

P-27
The following procedure is recommended for setting of top / bottom wedges:

1. Sufficiently loosen the 2 nos clamping bolts provided on each adjustable top / bottom wedge
mounted on shutter to allow the wedges to slide.

2. Tap the adjustable wedges lightly with hammer directly from the top to ensure that the adjustable
wedges mounted on shutter sit properly on the fixed wedge mounted on frame.

3. Tighten the clamping bolts of moveable wedges in place.

4. Carry out this procedure for all the side wedges.

Note: When all the wedges are properly set, the clearance between the mating seat facings on the
shutter and the frame should not exceed 0.10 mm. Each wedge should be tightened to the same
degree. While tightening the adjusting screws, do not use a spanner/wrench longer than 8” (200
mm). Carry out the gap check carefully because the sealing characteristic of the installed gate
depends upon achieving this setting of keeping the gap minimum and uniform throughout the sealing
perimeter of the gate.

(C) PROCEDURE FOR FIELD ADJUSTMENT OF FLUSH BOTTOM CLOSURE

ARRANGEMENT: (If provided)

In case of flush bottom closing gates the invert of opening and the invert of floor in front of gate is
flush so that there is no water retention and water easily flows out. A recess is to be provided in front
of gate to enable mounting of gate on thimble and this recess is subsequently filled up with easily
removable lean concrete / asphalt so that if required the gate can be removed in future by chipping
away lean concrete / asphalt.

P-28
The dimension of recess shall be as shown in respective General arrangement and Block out detail
drawing for each gate. Refer figure ( y ) below to understand the flush bottom closure arrangement.

The flush bottom closure arrangement is properly set in the gate assembly at the factory prior to
despatch of gates. This setting should not be disturbed at site. However, sometimes this setting may
have to be field adjusted with a view to reduce the extent of leakage taking place due to slight
inclination of frame upon improper installation and resultant increase in gap between shutter end and
rubber seal or due to need of re-setting of wedges. Hence it may be necessary for the flush bottom
closure arrangement to be reset by the Buyer at his end, after the installation of gates or upon usage.

Setting the bottom sealing arrangement as well as the wedges on flush bottom closure gates requires
a slightly different procedure than in case of conventional gates.

First loosen all wedges so that there is no contact between the contacting faces of the wedges. Using
the operating mechanism the shutter should be lowered to compress the rubber seal to the degree
required for proper sealing. After the rubber is compressed, the side wedges as well as the top
wedges, if any, should be adjusted as described earlier.

CAUTION

Over-tightening of wedges should be avoided. If the wedges are set too tightly they will tend to raise
the shutter and allow leakage between the bottom edge of shutter and the rubber seal surface. When
all the wedges are properly set, the clearance between the mating sealing faces of the shutter and the
gate frame should be less than 0.10 mm at the top and sides and also the bottom edge of the shutter
should be able to firmly clamp a sheet of paper placed against the rubber seal at any point along the
invert.
-------------------------------------------------------------------------------------------------------------------------
-

P-29
 INITIAL OPERATION OF GATE AFTER COMPLETION OF INSTALLATION

1. Remove the lock plates / transit stop (painted in red) on the gate assembly before operating the
gate.

2. Clean the gate assembly thoroughly well. Remove all foreign matter, paint, sand, concrete
droppings, debris etc. from the sealing faces, wedging and sliding surfaces, gate guides, bottom
sill of gate and the invert. Every possible care should be taken to ensure that the seat-facings or
sealing faces are neither scratched nor damaged in any way otherwise the gate cannot be
expected to be adequately water-tight.

3. Thoroughly clean the lifting rod and lubricate with high grade heavy duty grease.

4. Check that the stop nut is set properly and secured as explained earlier in this manual.

5. Gate may be supplied with manual / electrical / pneumatic operating mechanism. Electric /
pneumatic operating mechanism may have manual override mechanism. The initial operation of
gate should be done manually and only if every thing is found OK, the subsequent operations
should be done electrically / pneumatically.

6. Manual operating arrangement may either be (a) Un-geared, (b) Single speed geared, or (c) Two
speed geared depending upon torque / efforts required to operate the gate. Please refer to figure
( z ) to get an idea about various types of manual operating arrangement.

In case of un-geared operating arrangement the handwheel should generally be rotated counter
clockwise ( This is as per JASH standard ) to open the gate and clockwise to close the gate.
Refer to the arrow mounted on the operating arrangement showing opening / closing direction.

Single speed geared or Two speed geared operating arrangement is generally provided with
removable type crank handle / hand wheel. In case of single speed geared arrangement the
handle has to be generally rotated counter clockwise (This is as per JASH standard) to open the
gate and clockwise to close the gate.
P-30
 In case of two speed geared arrangement, mount the crank handle / handwheel on the pinion
shaft at the right side for initial crack opening of the gate requiring high torque. After opening
the gate by about 50 mm (2”) the torque requirement will significantly reduce and hence the
balance gate opening can be done faster after mounting the crank handle / handwheel on the
pinion shaft on the left side. After mounting the handle on the left side pinion, rotate the handle
in anti-clockwise direction to further open the gate. (WARNING: Rotation in the clockwise
direction after mounting handle on left side pinion shaft will close the already crack
opened gate instead of further opening the gate).

7. For electric / hydraulic / pneumatic actuating arrangement refer to the supplier’s manual for
understanding the procedure to be used for operation of their equipment.

8. Now operate the gate slowly and carefully from fully closed position to fully open position to
check for unobstructed and smooth operation of gate as well as headstock.

9. Ensure that while operation the spindle is not touching the stem guides.

10. After the gate is fully opened, check seat facings or sealing faces and clean any foreign matter
like paint, concrete etc that is found sticking on the gate.

11. Close the gate again and recheck the clearance between the mating seat facings or sealing faces
of the shutter and the gate frame. The clearance / gap should be less than 0.10 mm at the top,
sides and also the bottom. If gap is observed more than 0.10 mm then reset the wedges where
provided or rectify the frame installation.

With above procedure the gate is ready for commissioning.

-------------------------------------------------------------------------------------------------------------------------

P-31
 MAINTENANCE INSTRUCTIONS:

1. The gate should be operated at least once in every three months.

2. Rising spindle gates do not require periodic maintenance. Non rising spindle gates require
periodic attendance and maintenance. Spindle threads of non rising spindles remaining
submerged may get coated with dirt and grit. This wears out the threads of the spindle nut faster.
Hence the spindle threads and nut should always be kept clean and greased. The spindle nut
should be thoroughly checked at least once every six months and should be replaced if excessive
wear is noticed.

3. The lifting rods of all headstocks should be cleaned and greased at least once every six months.
The frequency of cleaning and greasing the lifting rod should be increased if the grease is
observed to become dirty faster.

4. The thrust bearings and gears of manually operated headstocks should be lubricated with heavy
duty grease at least once a year. For electric / hydraulic / pneumatic actuating arrangement refer
to the supplier’s maintenance manual for carrying out routine maintenance.

-------------------------------------------------------------------------------------------------------------------------

P-32
 “DO’S AND DON’TS”

“DO’S”

1. Before Sluice Gates are put into regular service or after being left standing for any considerable
length of time the gate shutter should be raised and all foreign matter carefully removed from the
faces, guide grooves and the invert area.

2. The sealing faces, wedge faces, screwed stems and any other machine parts should be well
greased.

3. All Sluice Gates should be operated at least once every three months.

4. The nuts of all constructional and foundation bolts should be checked for tightness every twelve
months.

5. If the Sluice Gate is installed in situations where debris or foreign matter can build up it is
recommended that the sluice gate be periodically cleaned off.

6. The protective paint on all painted items should be examined every six months for signs of
damage.

7. For rising stem units, with the gate in the fully raised position, the screw thread should be
cleaned, inspected for wear and re-greased every six months.

“DON’TS”

1. Do not remove lock plates until and unless the gate is installed and is to be initially operated.

2. Do not forget to set the stop nut in the correct position as mentioned in the manual.

3. Do not over torque the crank handle/handwheel.

4. Do not disturb the adjustment of wedge block bolts/studs.

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-

P-33
 TROUBLE SHOOTING AT SITE

There are a number of problems that can arise with gates at site. We are giving some of these
problems and the methods of repair. Hence before requesting a site visit of the manufacturer’s
representative, the contractor should check the problem faced and carryout trouble shooting as
per guidance given hereunder.

(A) Leakage:

Leakage is the problem that is most often encountered. However some leakage is permissible for this
product and hence do not expect zero leakage. Hence before requesting a site visit, the contractor
should check the quantum of leakage. Please verify the permissible leakage norms as per the
standard against which the supply is made or verify from specifications and agreed
permissible leakage norms by JASH. If the leakage is observed to be within permissible limits
then there is no need for a site visit

Leakage at site is mostly a result of improper erection (installation) or damage to the sealing
arrangement. If the erection has been done correctly, without twisting and distorting the frame in
case of wall mounting gates or without twisting and distorting the wall thimble in case of wall
thimble mounted gates, then proper adjustment of the wedges will most often correct the problem.

Hence before requesting a site visit, the contractor should adjust the wedges and recheck the leakage
performance. In addition to this he should check the following:

1. Check for any damage to sealing arrangement. If seals are found damaged then replace them.

2. Check for paint or other foreign substance on the seat facings or sealing area. It is not
difficult to get paint on the seat facings even in our shop, and hence in the field it is very
difficult to avoid paint or foreign matter from coming over the seat facings while installation
or carrying out subsequent civil works and painting after installation of gates.

3. First check the seat facing on the top side by looking over the top of the gate. If there is paint
or other foreign substance on the seat facings of frame and shutter then this should be
cleaned. Thereafter raise the gate so that the seat facings on the frame as well on the shutter
can be examined. If anything is sticking on the seat facings / sealing surface then scrape and
remove the same without damaging the surface.

After cleaning the seat facings / sealing area it may be sometimes necessary to reset the
wedges.

4. Leakage from the bottom in case of flush bottom closure gate can be on account of collection
of concrete or asphalt on the flush bottom seal top or on the machined face of support bar or
shutter. The solution is to scrape and remove this foreign material without damaging the seal
while doing so.

5. If it is a flush bottom closure gate and there is leakage at one or more points at the invert,
then raise the gate and check for distortion of the seal. If a gate is kept propped open for a
period of time, there is a possibility that the resilient seal will distort and leakage will result.
P-34
 The only solution is to change the seal. An oversized seal will be sent to the contractor and
he will have to remove the old seal, cut the new seal to the same length, place the seal
retainer bar on the seal and drill the holes. The new seal would then be attached using the
same retainer bar and bolts.

6. If the gate leakage is concentrated in one area or if it is all across the top, or down one side,
check for distortion of the gate.

If the frame is distorted, then by tightening the wedges with considerable force, it may be
possible to stop the leakage through the gate. However this may not be right approach if the
distortion is high because in such cases, when the gate is opened and closed again, it will not
be possible to close the gate completely and leakage will reoccur. This is because enough
force can be exerted on the wedges when they are being adjusted to distort the disc so that it
matches the distorted frame. However, when the disc is subsequently forced into the wedges
by the hoist there is not sufficient force to distort the disc.

The way to check for distortion is to check the spacing between the seat facings with a feeler
gauge, making measurement around the gate. This can be done from the frame side of the
gate quite easily. After the measurements have been taken, the nuts holding the gate to the
wall thimble or to the wall should be loosened, particularly in the area where the leakage is
most severe. If the frame is distorted, it will spring back into shape when the nuts are
loosened and the clearance between the seat facing will lessen.

7. Frame distortion occurs frequently where the sluice gates are mounted on civil walls. The
mounting face of these walls is generally not flat.

The only sure correction we know of is to move the gate away from the wall a short distance,
perhaps 5 mm or so. Put shims between the gate and wall all the way around the frame,
tighten the nuts that hold the gate to the wall evenly and check for clearance between the seat
facings. If the clearance is less than 0.1 mm, then the gate is properly installed. The next step
is to seal the space between the gate frame and the wall with special epoxy grouts available
for such purpose. This will prevent leakage between the flange and wall.

8. If leakage persists after the wedges are adjusted and it does not appear to be distortion of the
gate, then check for leakage between the flanges or around the frame. Sometimes the wall
thimble is not firmly embedded in the concrete and water will leak between the wall thimble
and the concrete.

9. If the gate is a small gate under unseating head conditions, and it has no top wedges, leakage
can occur along the top of the gate if there is too much force put on the stem. This can be
determined by backing off on the hoist so that the force on the disc is decreased. The leakage
should decrease. In this case, the stop collar should be adjusted close to the operating nut so
that it will limit the amount of force that can be placed on the disc.

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(B) Noise:
The second major complaint may be noises coming from the gate during operation.
1. A high pitched squeal or rubbing noise - This is normally encountered where the stems have
not been lubricated. The solution is to clean and thoroughly lubricate the threaded section of
stem. A rubbing or squealing noise can also be obtained where the stem passes through the
stem guide. This can be corrected by coating the stem with heavy, gummy, water proof
grease.

A stem that looks well lubricated may still be causing some trouble if it is covered by a steel
or galvanized steel pipe cover. Rusting takes place within the pipe cover and rust particles
drop into the grease. Rub the grease between your fingers to determine whether or not there
are particles. If there are particles in the grease, the old grease should be cleaned off and the
stem lubricated. Also, the pipe covers should be well cleaned and painted inside or hot
dipped galvanized.

2. Chatter - Chatter can be caused by stems not properly lubricated and by the stem rubbing on
stem guides during the operation. Chatter will also be heard where gates are operated under
high head conditions and they are being opened from the fully closed position. With very
small openings, vibration can be set up because of high velocity beneath the gate has been
opened a few inches. There is nothing much that can be done about this and it is not
generally harmful.

3. One shot noise on opening or closing - Sometimes, when the gate is being pulled from the
wedges, there will be a loud crack or bang. This will occur on occasion when the gate has
been pushed into the wedges with considerable force. This is not a harmful noise and will not
damage the gate. In the closing direction, in some hydraulic conditions, the gate disc will be
held in the open position. This can normally be due to a head on the gate greater than the
weight of the disc. The gate will then be pushed downward by the thrust nut and this may
allow the gate, once it is in motion, to overcome the water load and drop the short distance
between the thrust nut and the rib. This may be repeated two or three times, but will normally
stop after the gate is partially closed.

4. If the nuts on the bolts holding the floorstand to the concrete are not tight, there may be some
vibration and noise.

(C) Gate will not operate or operates with difficulty:

This is a third major category which can involve a number of problems.

1. If the gate will not open at all, the lock plates may still be on the gate.

2. If the gate will not open, but the stem moves, then the stem block / connecting block has
become disconnected from the end of the stem or the coupling has been disconnected. The
most common cause of this is not tightening the locking bolt given on the stem block to the
threads of the stem or not securing the locking pin (bolts) between the stem coupling and the
stem. The solution is to tighten the locking bolt in case of stem block or secure the locking
pin (bolts) in case of coupling.
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3. If the gate has been fully opened and will not close, the gate may have been opened too far
and jammed the stem threads into the stem operating nut. This can normally be freed by
putting a strain on the crank and closing the gate and tapping the top of the stem.
 4. The gate will not close all the way. The most obvious problem would be an obstruction
beneath the gate. However, this would probably flush out if the gate were raised again and
then lowered. If the gate has top wedges, it is possible to have debris caught between the
flanges in the area of the top wedge seat. This can prevent the gate from closing all the way.

5. Difficulty in operation is normally caused by binding or lack of stem lubrication. Lack of

stem lubrication doubles the force necessary to open the gate. Binding can occur in the gate
guides if the upper gate guide anchor bolts are tightened improperly. The binding in this area
can also occur if the wall thimble is not installed properly and the centerline of the gate is not
vertical.

6. Difficulty in operation is normally caused also due to bending of stem. Lack of straightness
in stem results into its rubbing at stem guides and increases the force necessary to open the
gate.

7. If the pinion shaft on the operator turns and the stem doesn’t move, the teeth on the gears
have been stripped. This is sometimes caused when far too much torque output is used to
operate these gates or when the spindle or gate alignment is not proper.

(D) Problems related to stem:

This is the fourth major category which can involve a number of problems associated with bending
of stems or non- matching of threads of stem, stem nut, coupling or stem block.

1. Stems found bent after un-packing: Stem are checked for straightness before packing and are
still sometimes found bent. The reason for this can be improper support to the entire length of
box while transportation, improper handling while trans-shipment or due to improper storing
at site resulting into minor bending of stems. Any minor bending in stems should be
straightened at the site before using such stems.

2. Tendency of the stem to bend due to over closing: The first thing to check for is the setting
of the stop collar. The stop collar should be on the stem approximately 1.5 to 2 mm above the
operating nut with the gate in the closed position. This will prevent the over closing of gate.

Secondly the location of the stem guides should be checked to insure that the spacing
matches the spacing indicated on the installation drawing. The stem guide should be
tightened on the bracket. If this is loose, then the stem is not receiving any support from the
bracket and is bending while over closing.

If the stem is already bent, it may not be beyond repair. Bent stems can be straightened
successfully at site if the bending is minor or under a press if bending is more.

3. Difficulty in mounting of stem nut, stem block and coupling over threaded portion of stems:
The first thing to check for is whether there is any burr or breakage of the initial thread which
is creating obstruction in mounting. If this is the reason then remove the same and clean the
threads so that threads engage easily.
END OF MANUAL
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