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
‘JASH’ S.S. OPEN CHANNEL SLUICE GATES

Manual Code: SIOM-SS-OCG-M/E-180

CLIENT : VA Tech Wabag Ltd.

PROJECT : Illugin Phillipines Project

 INSTALLATION, OPERATION AND MAINTENANCE MANUAL
FOR
‘JASH’ S.S. OPEN CHANNEL SLUICE GATES

INDEX

SR. DESCRIPTION PAGE

NO. NOS.

1. INDEX PAGE 1

2. INTRODUCTION, UNLOADING AND UNPACKING, HANDLING 2–5

AND STORAGE.

3. INSTALLATION PROCEDURE FOR WALL MOUNTING / WALL 6 – 13

THIMBLE MOUNTING GATES.

4. FIXING OF LIFTING RODS/SPINDLES/STEMS, COUPLINGS, 14 – 22

GUIDE BRACKETS AND MANUAL / ELECTRIC GATE
ACTUATING MECHANISM.

5. INITIAL SETTING OF TRANSPARENT PIPEHOOD TYPE GATE 23 – 24

OPENING INDICATOR FOR RISING SPINDLE GATES.

6. FIELD ADJUSTMENTS 25 – 26

7. INITIAL OPERATION OF GATE AFTER COMPLETION OF 31

INSTALLATION & MAINTENANCE INSTRUCTIONS

8. DO’S AND DON’TS 32

9. TROUBLE SHOOTING 33 – 36

-1-
INSTRUCTION MANUAL FOR JASH STAINLESS STEEL OPEN CHANNEL SLUICE GATES

INTRODUCTION :

This manual describes recommended methods of handling and storage, installation, initial operation,
precautions for maintenance and safety of JASH side wall embedded /side wall anchored/face wall
mounted manually or electrically operated Stainless Steel Open Channel 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.

Open channel gate is custom made equipment comprising of many number of parts, components and
accessories viz. Gate assembly comprising of frame, shutter etc, and Lifting mechanism comprising of
operating headstock, lifting rod/spindle/stem, 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 side wall embedded /side wall anchored/face wall mounted manually or
electrically operated Stainless Steel Open Channel Sluice Gates. Technical details, data, figures 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 constant learning and updating. 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! the manufacturer immediately to know the weight or to clarify the doubts. The
lifting capacity of slings, chains, tackles, hoist, crane etc to be used for unloading and subsequent

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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 shortage 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 comes in direct contact
with chains and handling accessories made of carbon steel as this results into 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.
-3-
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. 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 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.

The spindle of self-contained / closed top frame gates {refer figure ( o ) 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 ( p ) to
understand what is a non self- contained / open top frame gate} are sent separately. Whether a gate is
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 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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 INSTALLATION PROCEDURE FOR OPEN CHANNEL SLUICE GATES

The supplied stainless steel open channel gates can be mounted (A) Directly on the face of wall
( Face Wall Anchored ), (B) between the walls ( Side Wall Anchored ) or (C) Mounted in a groove
between the wall ( Side Wall Embedded ). Please verify the type of mounting from the approved GA
drawing whether mounting (A) or (B) or (C) is provided. After ascertaining this, follow the
installation procedure (A) or (B) or (C) as given hereunder.

Before commencement of installation, check the civil conditions site for correctness of all dimensions as
shown in the GA Drawing / Civil Block out drawing furnished by JASH for the gate being installed.
Specially check whether the center line of the gate opening is as per GA drawing, check whether the size
of the opening of gate and block out where the gate is to be mounted is correct.

Also specifically check for the correct location of the hole provided in the floor platform for passage of
the spindle, if this type of headstock is required.

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 FACE WALL ANCHORED 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.

(i) Proceed if the face of the wall on which the flat back face of the gate frame is to rest can
be made flat within 2 mm (1/16”). (Bear in mind that the gate should not be bolted directly
to an uneven surface of wall because even a very small amount of gate distortion will cause
excessive leakage.)

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1. Before the gate is brought for installation, check the flatness of the face of wall around the gate
aperture / opening where the gate frame flange is to rest. Ensure that this area is flat within 2 mm
(1/16”). Refer figure ( d ) above to understand this requirement.

2. 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 ( d ) below to understand how a
steel template can be made for ease in hole drilling on wall.

In case of 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.

3. Offer 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.

4. 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
-7-
 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.

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

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

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

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

9. 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 ) above showing cross section at frame extension guides.

10. 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 packing or wedges only where the gap is more than 0.1
mm and the packers 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.
-8-
 (ii) Procedure to be followed if it is not possible to make the face of wall flat within 2 mm
(1/16”) on the area where the gate frame flange is to be mounted. (Bear in mind that the
gate should not be bolted directly to an uneven surface of wall because even a very small
amount of gate distortion will cause excessive leakage.)

1. Follow the procedure from point A ( i ) 1 to A ( i ) 6 as stated above.

2. 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 ( g ) above to understand how the shims
are to be used to locate gate flange in a vertical plane away from face of wall.

3. 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.

4. 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.

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

6. 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 well allowing atleast 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.
-9-
7. Tighten carefully the anchor bolt nuts without straining the gate frame. Check the plumb in all
directions.

8. 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.

PROCEDURE FOR TIGHTENING OF NUTS :

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

 Refer figure (h) 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.

 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
( i ) 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.
- 10 -
 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 wall.

With the above procedure the tightening of nuts is complete.

(B) INSTALLATION PROCEDURE FOR SIDE WALL EMBEDDED GATES :

1. Before the gate is taken up for installation check for the completion of civil works. Check that the
grooves/recesses as shown in the G.A. drawing are made in the sidewalls and bottom floor of the
channel. It should be ensured that the grooves provided on the sidewalls are parallel to each other
and square with respect to bottom of channel. Also check the distance between the bottom sill of
gate to the top of operating platform if the gate is not self contained type. If any discrepancy is
observed then suitable corrections should be carried out before proceeding further. Refer to figure
( j ) below showing cross section of gate frame embedded in grooves in side walls.

2. Lift the gate assembly and carefully lower it in the grooves of the sidewall.

3. After fully lowering the gate, ensure that the gate sill is in level with the floor of channel. Also
ensure that the side guides of the frame are at an equal distance from the face of the sidewalls of the
channels and that the gate is in vertical plumb. The above can be ensured by putting suitable
support blocks on the required sides ensuring that the gate remains steady on its own.

4. Check the squareness between the bottom sill and side guides of frame as well as distance between
the side guides to ensure that it has not got disturbed during the above process.

- 11 -
5. Shutter up the gap between the side walls and either sides of the frame guides along the two vertical
walls of the channel and floor of the channel.

6. Carefully pour the fluid grout in the gaps between the frame guides and the side walls and in the
gap below the bottom sill of the gate frame. While pouring the grout ensure that no grout goes
inside gate assembly.

7. Recheck the plump and alignment of the grouted segments to confirm that the initial setting is
correct. If not correct, break open the fresh concrete to remove the gate. Thereafter once again carry
out the above mentioned procedure and get the correct installation of gate.

8. Finally if setting is correct allow grout to cure thoroughly atleast six clear days for proper curing.

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

(C) INSTALLATION PROCEDURE FOR SIDE WALL ANCHORED GATES :

These gates are mounted on the side of 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 gate manufacturer before casting of wall and thereafter reinforcement bars so
positioned that they do not foul with holes to be drilled subsequently.

Procedure to be followed if the face of wall around the gate aperture on which the flat face of the
gate frame is to rest can be made flat within 2 mm. (Bear in mind that the gate should not be bolted
directly to an uneven surface of wall because even a very small amount of gate distortion will cause
excessive leakage.)

- 12 -
1 Before the gate is brought for installation, check the flatness of the face of wall around the gate
aperture / opening where the gate frame flange is to rest. Ensure that this area is flat within 2 mm.
Refer figure (--) above to understand this requirement.

2 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.

3 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 ( l ) below to understand how a
steel template can be made for ease in hole drilling on wall.

4 Offer template upto the installation position and carefully locate it after ensuring that template is
properly positioned vertically using plumb line and centre line marks.

5 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 correct size suiting the diameter
of the anchor fastener should be made to the depth as shown in 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.
- 13 -
 6 Secure the anchor fasteners in the wall following the procedure recommended by the anchor
fastener manufacturer.

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

8 Lift the gate assembly with the rubber gasket pasted on its back and put in place over the anchor
bolts.

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

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

11 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 packing 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 packing or wedges 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.

With the above procedure the installation of gate assembly on wall 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
- 14 -
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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 INSTALATION OF LIFTING RODS /STEMS /SPINDLES
& MANUAL / ELECTRIC GATE OPEARTING 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 ( o ) 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.

In case of 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.

In case of gates provided with ungeared headstocks only the handwheel may be required to be
fitted to enable operation of the gate. For this following procedure is used:
- 16 -
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 ( p ) above. 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, it is
very critical that stop nut is secured at the correct location as stated above.

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

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

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 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 ( r ) 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 eye hole in position, insert the pin through the lugs and horizontal boss eye hole of
stem 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 ( r ) 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.

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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 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 20/25
mm ( 3/4”/1”). 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 ( p ) 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, it is very
critical that stop nut is secured at the correct location as stated above.

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.
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 By following the above procedure the fixing of lifting rods with the manual operating mechanism is
complete.

 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 ( s ) below.

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

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.

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.
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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 and after alignment operates 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 ( p ) Once the stop nut is set in its position secure it there with the help of
set screw provided on 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 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.

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 ( t ) below.

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

1. 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.

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For assembling the threaded spindle with the actuator two alternative methods as explained underneath
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.

2. Insert the threaded end of the stem into the actuator and ensure that about 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.

3. 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 should be inserted through the
matching holes on the coupling as well as the stem.

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 Put suitable shims between the platform top and the headstock base/Actuator pillar keeping a gap of
about 20/25 mm. Adjust the shims to maintain the headstock pillar in plumb. Check the alignment of
the stem with a plumb. 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.

4. 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.

5. 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.

6. Finally check the alignment of the stem with a plumb 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.

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 ( p ) Once the stop nut is set in its position secure it there with the help of
set screw provided on 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 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.

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.

WARNING :

Selection of Operating mechanism ( whether manual or electric) of each 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 improper
alignment of all these items may result into higher torque requirement than envisaged while
- 23 -
doing the selection of operating mechanism. This will in turn affect proper and smooth working
of gate for which JASH cannot be held responsible.

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

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 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 ( u ) below.

In case of ungeared 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.
- 25 -
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 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 the “C”/ “ Close” mark with indicator disc.

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- 26 -
 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, gate guides, bottom sill of gate and the invert. Every
possible care should be taken to ensure that the 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 a high grade heavy duty grease.

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

5. 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.

6. After the gate is fully opened check sealing faces and clean any foreign matter like paint, concrete
etc.

7. 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 0.10mm at the top, sides and
also the bottom.

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- 27 -
 MAINTENANCE INSTRUCTIONS :

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

2. Rising spindle gates do not require periodic maintenance.

3. Non rising spindle gates require periodic attendance and maintenance. Spindle threads of non rising
spindles remaining submerged may get clogged 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.

4. 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.

5. The thrust bearings and gears of manually operated headstocks should be lubricated with heavy duty
grease atleast once a year.

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- 28 -
 “DO’S” AND “DON’TS”

“DO’S”

1. Before Open Channel 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, screwed stems and any other machined parts should be well greased.

3. All gates should be operated atleast once every three months.

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

5. If the 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 should be examined every six months for signs of damage.

7. For rising stem units, with the gate in the fully raised position, one should have the screw thread
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 bolts/studs.

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- 29 -
 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 manufacturers
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. 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.

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

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 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 the 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.

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.

2. 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.

3. In case of flush bottom closure gate, 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 resilient seal will distort and leakage will result.

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.

- 30 -
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.

1. 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 caulk the space
between the gate frame and the wall with lead wool or special epoxy grouts available for such
purpose. This will prevent leakage between the flange and wall.

2. 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.

3. 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.

( B ) Noise :

The second major complaint may be noises coming from the gate during operation.

 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 steam 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
- 31 -
 lubricated. Also, the pipe covers should be well cleaned and painted inside or hot dipped
galvanized.

 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 constructions 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.

 One shot noise on opening or closing - Sometimes, when the gate is being pulled, there will be
a loud crack or bang. This will occur on occasion when the gate has been pushed 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.

 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 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 in case of coupling.

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.

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.

- 32 -
 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 or stem block.

1. Stems found bent after unpacking : 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.

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 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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