Mueller Hydro gate hg561 Instruction Manual

CAUTION:

This manual describes the recommended procedures for installation, adjustment,

operation and maintenance of Hydro Gate gates. When it is used in conjunction with

installation drawings that have been supplied by us, this manual will be sufcient for

most installations. Proper care and precautions must be taken in handling and storing

the gates at the delivery site. For further details on the handling, storing, and installation

of a specic project, contact the Hydro Gate headquarters.

Precise and accurate installation is critical to satisfactory operation. We assume no

liability, expressed or implied, for interpretation of the contents of this manual. If

you have any questions concerning the interpretation of the contents of this manual

or installation procedures in general, you should contact the Hydro Gate facility in

Colorado. We expressly disclaim all liability, expressed or implied, for faulty installation

of any gate or associated equipment and for any direct, consequential, or incidental

damages that may result.

F 13922 1/19

TABLE OF CONTENTS PAGE

General Information 2

Installation 2-8

Operation 9

Maintenance 10-11

Leakage / Troubleshooting 12-13

Storage 13

Parts 14-16

HG561 Fabricated

Slide Gates

OPERATING INSTRUCTIONS MANUAL

The purpose of this Installation,

Operation, and Maintenance

Manual is to provide information

on the correct procedures for

installation, adjustment, operation,

and maintenance of Hydro Gate

HG561 Fabricated Stainless Steel

Gates and their component parts.

The gate, lift, and accessories were

accurately machined, fabricated,

assembled, adjusted, and

inspected before leaving the Hydro

Gate factory. For best results, read

and follow the applicable parts of

this Manual carefully, including

thorough cleaning and lubrication

of moving parts and final wedge

adjustment. If the gate will not be

installed immediately, consult the

long-term storage instructions.

NOTE: DO NOT disassemble the

gate or lift for installation.

Safety Precautions

To help ensure your workers’

safety, We recommend the

personnel responsible for

installation, operation, and

maintenance of the gates for

this project read and study the

instructions and precautions in

the Installation, Operation, and

Maintenance Manual, and follow all

directions carefully. The following

are major items associated with

safe installation, operation, and

maintenance of this slide gate.

• DO NOT operate equipment

before carefully reviewing the

Installation, Operation, and

Maintenance Manual.

• Always use proper equipment

when lifting or unloading heavy

items.

• DO NOT stack equipment too

high for storage. Always use heavy

wood blocking between equipment.

Refer to the storage instructions

contained herein for details.

• Adequately support and brace

OVERVIEW

INSTALLATION

Note: Installation and/or

operation of the gate lift and stem

without proper lubrication will void

the equipment warranty. Thorough

cleaning of the stem and sealing

surfaces is required before gate

operation. Details are described

in the appropriate sections of this

Manual.

Spare Parts

We do not recommend the stocking

of spare parts. If spare parts are

required see “Spare Parts List”

(page 14). Replacement parts are

readily available for worn or broken

parts. Contact us or our Hydro Gate

representative in your area.

Special Tools

Special tools are not required

to operate and/or maintain the

heavy items during placement of

equipment.

• Wear proper personal protective

equipment (PPE) and clothing when

working on or around gates, (e.g.,

hard hats, heavy boots, safety

glasses, and breathing apparatus,

if necessary).

• NEVER place bodily obstructions

in the path of moving parts. When

operating gates and accessories,

stand clear of all moving parts.

Serious injury can result from

contact with moving parts.

• Use caution when performing

operations and maintenance.

Watch for loose or damaged

parts. Stop all functions until any

damage has been corrected.

• DO NOT use any mechanical

devices other than the factory-

supplied equipment to operate the

gates for this project.

• DO NOT attempt operational

procedures other than set forth

in the Installation, Operation and

Maintenance Manual.

equipment supplied by us on this

project.

Parts List

Prices for individual parts and/or

assemblies may be obtained from

Hydro Gate sales at the time that

they are needed.

Disassembly

We do not recommend the

disassembly/reassembly of any of

the equipment on this project.

Emergencies

Emergency/shutdown procedures

do not differ from normal operating

procedures for this project. If

you should need assistance,

please contact the Hydro Gate

Field Service Department at

303.288.7873.

• Contact your Hydro Gate

representative with any questions

you may have regarding safety in

installing, operating, and handling

Hydro Gate products.

To Ensure Proper Installation

We recommend that personnel

study these instructions and

installation drawings and follow

the installation directions carefully.

This gate is shop adjusted, quality

checked, and designed for low

leakage. Attention must be given

to proper storage, careful handling,

and accurate location of embedded

items for this gate to operate as

designed.

1. Read and follow the Installation

instructions and drawings in this

Manual.

2. Carefully inspect the gates

and accessories when received,

before unloading trucks or cars.

Report ALL shortages or suspected

damage by marking the bill of

lading and receiving reports at this

time. Latent shortages must be

HG561 FABRICATED SLIDE GATE

General Information / Installation

reported in writing within 30 days

of shipment.

3. Store gates evenly on planks or

timbers. Even large fabrications are

subject to permanent warpage if

unevenly blocked during storage.

4. Support full length of stems and

protect threads during storage and

handling.

5. Accurately locate and brace

embedded items during placement

of concrete.

6. Contact your Hydro Gate

representative with questions

regarding this gate. We have 100

years combined experience in the

water control industry.

7. DO NOT disassemble the gates

for installation.

8. DO NOT allow excess concrete

to overlap gate thimble or frame.

9. DO NOT Tighten nuts for studs

unevenly, or try to pull a gate frame

tightly against an uneven wall

surface. This, in most cases, will

cause excessive leakage.

10. DO NOT operate gates with

concrete and debris on them.

11. DO NOT operate gate stem dry

(without grease).

Gate Mounting

HG561 Fabricated Stainless Steel

Gates are most commonly mounted

on stud anchor bolts and grout

pads; however, they may also be

mounted on a fabricated thimble

or flange or on machined flanges

and thimbles. The gate flange

is not machined. A thick layer of

hard setting mastic is required

between gate and the thimble or

pipe flange. Recommended mastic

is polyurethane sealant such as

Sika-Flex 1A or equivalent. See

manufacturer requirements for

curing. Fast cure polyurethane

sealants, such as Loctite marine

grade, are available. They are a

good alternative; however, their

fast setting property requires

quick, well-planned installation and

cleanup of hardened material is

difficult.

Foam (Polyurethane) gasket may

also be used. Consult the Hydro

Gate engineering department for

additional information.

NOTE: Mastic is not furnished

by us.

Flanges for gate mounting must be

flat (non-warped) within +/- 1/16”.

The gate can function with some

twist/warp/non-flat conditions. The

larger the gate, the more out-of-

plane conditions can be tolerated.

Consult factory for extreme limits.

Mounting the Gate on Concrete

Surface with Adhesive Type Stud

Anchors

1. Use only adhesive-type or

epoxy-grouted studs. Mechanical

wedge studs are not recommended

and gate performance cannot be

guaranteed with wedge-type studs.

We usually furnish the all-thread

studs but does not furnish the

adhesive capsules or cartridges.

IMPORTANT: Adhesive such as

Hiti HY200 or HIT-RE 500-SD

are not supplied by us due to its

stringent storage requirements

and limited shelf lifetime.

2. Accurately layout positions

of studs or use the gate as a

template.

3. Drill holes to diameter and depth

required for size studs used. If

rebar is encountered during drilling

causing an impossible completion

of hole, consult the owner’s site

engineer for instructions on how

to proceed; cutting of rebar may

not be permitted. In some cases,

a new hole (or holes) may be

field drilled in the gate frame to

compensate for out of position

studs. Consult the Hydro Gate

engineering department for advice

and limitations.

4. Blow and brush all holes clean

according to adhesive system

instructions and place studs

with adhesive. Maintain proper

projection and alignment and allow

sufficient cure time, particularly in

cold weather.

CAUTION: Because of the

dynamic/reversing load on the

gates involving unseating or

seating loads and the use of front

and back nuts for alignment,

wedge studs are not satisfactory

since they require tension in

them at all times to “grip” the

concrete. The loss of “tension” in

the wedge stud may cause them

to fail.

5. Two nuts are provided for each

stud bolt (Fig. A). These are for

precise plumbing and alignment

with a nut on both sides of the

gate flange.

HG561 FABRICATED SLIDE GATE

Installation

Slide Plate

Adjusting Bolt Assembly

Gate Frame

Side Seal Retainer

Grout

Epoxy Anchor

Side Seal

Load Pad

Top Nut

Adjusting Nut

TOP VIEW OF STUD BOLT MOUNTING

6. Check the placement and

plumbness of pattern of stud bolts.

Fit check the gate onto stud bolts.

Perform minor bending adjustment

to studs, as needed.

7. Clean stud bolt threads. Apply

anti-galling compound (anti-seize)

and run one nut on each stud up to

or near the concrete.

8. Establish a plumb/vertical plane

with back nuts starting with the two

upper corner stud bolt back nuts.

Leave room for grout and some in/

out adjustment from the wall. With

plumb line or builder’s level and

straight edge, bring all other nuts

to a vertical plane established by

upper corner nuts.

9. Being sure flange of gate is

clean, place the assembled gate

over/on the stud bolts. Run the

front nuts on stud bolts until they

touch the gate flange.

10. Take note of how well the

gate frame fits the previously

established flat vertical plane of

back nuts on studs. Some variation

of the free-hanging gate flatness

is normal (1/8” in small/medium

sized gates; 1/4” in large gates).

11.Tighten the front nuts on side

studs until frame contacts back

nuts. Tighten the frame flange

between the two nuts.

12. Note that the gate slide should

be in tight contact with seals at

horizontal frame members. Some

curvature or non-flatness of frame

member may be required for good

seal contact with the slide. Tighten

front and back nuts up to the

flange while observing that no gap

between the slide and horizontal

frame seal exists or develops.

13. Grouting of gate frames is not

recommended until after the lift

and stem has been installed and

gate has been cycled open/close

to ensure smooth operation.

14. After operation has been

verified, carefully pack the space

between the gate and the wall

around the opening with “non-

shrink” grout. Alternatively, the

space may be formed and slurry

grouted with concrete. Grouting

behind the frame guide (legs)

extensions is not necessary.

15. Be sure the frame extension

stud bolts are in place and front

and back nuts are tight and hold

the frame stable.

Wall Thimble Installation

1. Place the wall thimble in the

correct position in the forms

and block it in this position. The

top centerline of the thimble is

stamped on its flange face. The

bottom centerline is also marked.

2. Plumb the front face of the

thimble using the marks indicating

top and bottom centerline. This

face should be plumbed with

respect to final location of the

gate, stem, and lift. “Plumb” is a

relative term, more precisely the

thimble gate and operating system

consisting of stem, stem guides

and lift must be in close co-linear

alignment. Alignment tolerance

is +/- 1/8” over the travel of

gate (gate opening height). True

or perfect plumb is primarily for

aesthetics and simplification of

installation and alignment.

3. Studs furnished for attaching

the gate may be used in the

attachment of the thimble to the

forms. If these studs are not used,

threaded holes in the thimble must

be plugged to prevent concrete

from entering them.

4. Use timbers or other bracing

material on the inside opening of

the thimble while concrete is being

poured (Fig. B).

NOTE: Use extreme care in

placing of these supports to

prevent warping of the thimble.

5. Pour concrete, being careful not

to tilt the thimble from its original

position in the forms.

6. Remove forms and bracing.

Installation on Thimble or Flange

with Machined or Non-machined

Face

1. Clean face of thimble with

scrapers and stainless steel wire

brush so no sand, concrete, dirt, or

foreign material are present

(Fig. C).

2. Check for plumb, flatness, and

warp with builder’s level or straight

edges. Flatness should be within

+/- 1/16”. If not, consult the

Hydro Gate engineering department

or field service department for

recommendations.

3. Install mounting studs in

thimble/flange face.

HG561 FABRICATED SLIDE GATE

Installation

FRONT AND SIDE VIEW OF THIMBLE

SHOWING BRACING

Provide timber blocking as

required to support thimble

during pouring.

Plumb thimble in forms

using top and bottom.

FRONT CROSS SECTION OF “F” WALL

THIMBLE – TYPICAL INSTALLATION

Clean Front

Machine Face of Thimble

Tapped Hole in

Thimble

Concrete

or Grout

4. Fit check the gate onto the

thimble to be certain the gate sits

well on its face without obstruction

from surrounding concrete.

5. Apply heavy layer of hard-setting

mastic so entire contact face

of frame flange will be covered.

A layer 1/16” to 1/8” thick is

usually sufficient. Excessive

thickness results in more cleanup;

too thin may result in flange

leaks. Recommended mastic is

polyurethane sealant such as

“Sika-Flex 1A”, “Bostik 920 marine

grade polyurethane”, “Devcon

Flexane 80 trowelable grade

putty”, or equivalent. Asphalt (tar)

mastic may be used in lieu of

polyurethane except in potable

water.

NOTE: See manufacture

instructions for proper cure times

before submerging. Fast cure

polyurethane sealants such as

“Bostik 920 Fast Set” or “ADCO

Fast Cure” are available. These

are a good alternative, however,

their fast setting property requires

quick, well-planned installation

and cleanup of hardened material.

Rubber gaskets may be used for

thimble mounting in conjunction

with sealants consult the Hydro

Gate engineering department for

additional information.

NOTE: Mastic is not supplied

by us.

6. Mount the gate over studs,

install nuts and tighten. Anti-seize

compound is recommended. See

Torque Table for approximate bolt

nut tightening. Precise torque

tightening is not required.

7. Check the squeeze-out of mastic

on the inside and outside of the

flange and clean off excess. No

squeeze-out indicates insufficient

mastic and likelihood of future

leak.

8. Allow sufficient cure time of

mastic before applying water

pressure to the gate. (see

manufacturer instructions).

Installation Of Flush Bottom

Closure Gates

Gates that are to be installed with

bottom frame members embedded

in the concrete are furnished with

a rubber seal attached to the

invert of the gate frame (Fig. D).

The top surface of the rubber seal

is installed at the same elevation

as the invert of the gate opening.

Refer to the Hydro Gate installation

drawing.

1. Form a recess for the bottom

of the gate in the original pour

of concrete. The dimensions of

this recess are shown on the

installation drawing.

2. After the forms are stripped,

install the gate as shown for

other types of installations in this

Manual.

3. After installation is completed,

non-shrink grout in around seals

and frame. Ensure the flush

bottom seal is free and clear of

any foreign material.

HG561 FABRICATED SLIDE GATE

Installation

TABLE 1. Torque for Tightening Nuts or

Hex Bolts Used for Assembly

CAP SCREW

DIAMETER

TORQUE TO BE

APPLIED (lbs-ft)

3/8" 20

1/2" 45

5/8" 75

3/4" 125

7/8" 200

1" 300

1-1/8" 450

1-1/4" 500

1-1/2" 600

Adjusting Nut

Grout

Gate Frame

Support Gusset

Epoxy Anchor

Seal Retainer

Retainer Screw

Top Nut

VIEW OF GATE SLIDE AND INVERT SURFACE

Slide Plate

Bottom Seal

Installation of Gate Stem and

Guides

1. Install the stud bolts for the lift

and stem guides as shown on the

installation drawings. Check for

proper alignment of the lift, stem

guides, and gate. The lift stem and

gate stem block must be in vertical

alignment within 1/8" per each 10

feet of distance.

2. Provide opening with adequate

clearance in the lift platform for

the gate stem as noted on the

installation drawing.

3. Install stem guide brackets on

studs, but DO NOT tighten nuts.

Leave them loose so the bracket

can be moved for later alignment.

Loosen all assembly bolts

holding the collars to the bracket.

Stem guide collars are 2-piece

construction.

4. When more than one gate is

to be installed, stems may be of

different diameters or lengths.

Stems are marked and/or tagged

for each installation. Separate

the stems per individual gate

installation.

Note: Exercise care when handling

and installing threaded stems;

nicks or burrs will damage lift nut

threads.

5. Insert the stem block into the

gate slide pocket, if applicable.

6. Stems may be in more than

one piece to facilitate shipment

and installation. If two or more

pieces are furnished, they must

be installed in their proper order

from bottom to top to place splices

in correct location so they will not

interfere with the stem guides

when the gate is opened or closed.

Measure the stem section lengths

and install.

7. Lower the bottom section of the

stem into place through the hole

of the gate slide and thread it all

the way into the block and align

the keyways (Fig. E) or insert stem

connection bolt(s).

Note: Immediately insert the key

to lock the bottom section of the

stem to the block. (The key is

omitted on non rising stem gates.)

8. Place all of the succeeding

stem sections. Double-check the

installation drawings to ensure that

the stem guide collars are in the

correct locations. Join together with

splices as provided (Fig. F).

Note: Insert all bolts or keys in

each stem splice immediately

after sections are installed and

aligned to prevent one section

disconnecting from another when

the gate is operated.

9. Immediately before lowering the

lift over the threaded portion of

the stem, thoroughly clean off all

foreign material.

10. Lubricate stem threads with

recommended lubricants. Do not

leave lubricated stem exposed to

contamination before completing

the installation.

Lift Installation and Adjustment of

Stem Guides

1. Clean the threaded section

of the stem, removing all foreign

material, and lubricate with

recommended lubricant as

described in the “Gate Stem and

Guide” section of this Manual.

Note: Operation of the gate

assembly without proper

lubrication of the stem will void

the equipment warranty.

2. Raise the lift and lower it

over the previously installed and

lubricated threaded stem section.

When starting threaded stem into

the bottom of lift nut, care must

be taken to avoid damage to the

threads. Rough handling may result

in damage to the bottom edge of

the threaded lift nut and prevent

the stem from being threaded

into the lift nut freely. Hold the lift

to prevent its rotation. Turn the

handwheel or crank to lower the

pedestal onto its stud bolts.

Note: When all parts are cleaned,

the threaded lift nut will turn onto

the threaded stem with very little

effort.

3. Using shims, double nuts on

studs, or other leveling devices

under the lift, align the centerline

of the lift nut until parallel with the

stem centerline. Vertical alignment

of gate stem and the gate slide

stem block must be within 1/8"

per 10 feet of distance. Tighten

nuts on the studs uniformly.

HG561 FABRICATED SLIDE GATE

Installation

STEM CONNECTIONS TO GATE

Key

Stem Block

Stem

STEM WITH SPLICE

Key

Stem

Splice

Stem

4. The crank should turn freely for

two or three turns in each direction

until the clearance between the

top or bottom of the stem block in

the gate slide is taken up. If any

binding occurs during operation

of the lift with the slight vertical

movement of the gate slide, the

stem alignment should be checked.

Slight misalignment will cause

undue wear to the threaded lift

nut. When binding is not caused

by misalignment, recheck to be

certain all threads on the stem and

in lift nut are clean.

5. Place the two-piece stem

guide collars around the stem

above each bracket. Place the

bolts through the projection of

the bracket and the ends of the

collars. DO NOT tighten the bolts.

6. Grout under the lift (if required).

After the grout has set, tighten the

stud bolts uniformly.

Note: Before opening the gate,

clean all grout, stones or other

foreign material from the top of

the gate (or bottom in the case

of a downward opening gate),

and ensure gate stem and lift are

properly lubricated.

7. Turn the lift crank or handwheel

to open the gate, until the gate

slide has moved at least 2". The

stem is now in tension. Check the

stem to be certain it is straight.

Tighten the nuts on the studs

through the stem guide brackets,

center the stem guide collars

around the stem, and tighten the

assembly bolts holding the collars

in position on the brackets.

8. Move the gate to its fully

opened position and check the

position of the stems. If the stem

is being deflected by the collars, a

stem alignment problem exists and

must be corrected, indicating the

gate may not be plumb. Consult us

for ways to correct or compensate

for this condition.

9. Lower the gate to fully closed

position. Run the stop nut down

on top of the projecting threaded

stem until it contacts the top of

the lift nut or stem cover holder.

Back the nut up until 1/16" to

1/8" gap appears between the lift

and the stop nut to allow complete

gate closure as sliding and bearing

surfaces wear in.

10. Tighten the setscrews through

the stop nut to hold it in place (Fig.

G & H).

11. Install the stem cover,

indicator, etc., as required.

12. Check to see if the gate slide

is making full contact across the

bottom invert seal.

HG561 FABRICATED SLIDE GATE

Installation

HANDWHEEL AND STOP NUT

Handwheel

Pedestal

Stem Stem Nut

Order ID Tag

REMOVABLE CRANK

Stem Cover Adapter

Stop Nut

Sealed Gearbox

Lift Nut

Cast Iron Pedestal

Revolving Handle

Hand Crank

Installation of Tandem Stems

Some gates have wide openings

with relatively short gate heights.

When the installation drawings

show tandem lifts, install each lift

in accordance with the preceding

steps 1 – 5. After each lift has

been installed and each stem is

connected to the gate slide at

the bottom and the lift at the top,

proceed as follows:

1. Turn the input shaft of each lift

in the direction to open the gate

until each stem makes firm contact

with the top of its connection on

the gate slide.

2. Place a level on the top of the

gate slide and move one stem or

the other of the gate up or down

until the slide is completely level.

3. A tandem interconnecting shaft

is furnished to connect the two lifts

and cause them to act in unison

for raising or lowering the gate.

Loosen the fasteners on one of

the jaws of the flexible coupling

and slide it toward the center of

the shaft until the shaft can be

connected between the two lifts.

Complete the connection and

retighten all fasteners.

4. Move the gate slide up and

down by turning the input shaft

of one lift. Ensure the gate is

installed with its top level and that

the gate is moving freely.

5. Complete the installation of

any stem guides, lubricate the

stem, adjust the stop nuts, etc, as

described in the preceding steps

1 – 9 in the section entitled Lift

Installation and Adjustment of

Stem Guides for gates not self-

contained.

Gate Adjustment

This gate is equipped with low-

friction polyethylene (UHMWPE)

seats and guides. The seats

rest on a neoprene (rubber) pad

for cushioned gasketing to the

frame. Sealing at the side is

accomplished by pinching the

seal lips against the slide plate

using the compression of the

rubber gasket pad. Top horizontal

member seal (and also bottom, if

seals are 4-sided) are loaded by

the compression pad and assisted

with ensured hook-type wedges

on medium and larger width gates

(Fig. A & J).

This gate has been factory

adjusted. However, if the shake-

proof nuts have been loosened,

readjustment may be required.

Visual Tightness of the Seat

against the Side

No light should be visible through

the seat or measurable gaps

between the slide plate and the

seat. A .004" gauge may be

used to check the seat gap as a

starting point; however, the best

test and proof of performance

is an unseating hydrostatic

test. This gate is required to

comply with AWWA C561 leakage

specifications.

HG561 FABRICATED SLIDE GATE

Installation

Gate Frame

Grout

Anchor

Slide Plate

SIDE VIEW OF BOTTOM SECTION SHOWING SEAL ARRANGEMENT

Wedge Adjustment Bolt

Adjusting Nut

Top Nut

UHMW

Polymer

Seal

Neoprene Load Pad

Cast Stainless Steel Wedge

HG561 FABRICATED SLIDE GATE

Operation

General Operation Information

HG561 Fabricated Stainless Steel

Gates are used to control flow of or

retain a volume of water, effluent,

or other fluids. Typical applications

include industrial water treatment

facilities, municipal water

treatment facilities, irrigation,

dams, flood control, and many

other applications that require

tight, low leakage closing.

The simplicity of a slide gate

makes it a popular choice when

designing flow controls. From the

basic hand-cranked manual model

to the microprocessor-controlled,

fully integrated electric slide gate,

actuation consists of the basic

open or closed, or modulating

operation.

Depending on size, most slide

gates can operate without error

in diverse conditions. Some

extenuating circumstances may

include large amounts of ice or

other solids that will obstruct the

travel path of the gate. In most

cases, when the obstruction is

removed, normal operation can be

resumed without adjustment to the

gate.

Slide Gate Operation Procedures

The following sections cover the

general operating procedures

associated with two manual-

operation systems (handwheel

and handcrank). Read and follow

the operating procedures for the

applicable system. If you have

any questions concerning safe

operation of this HG561 Fabricated

Stainless Steel Slide Gate, contact

us immediately.

H2B Series Actuator (Manual

Handwheel)

OPENING – To open this slide gate

observe the direction of rotation

noted on the handwheel. Turn in

the direction of opening until the

desired gate position has been

achieved. Observe the relative

position of the top of the stem in

relation to the Mylar decal on the

stem cover (if equipped.) When

the top of the stem is equal to the

OPEN or 100% indicator the gate

is considered to be FULL open and

should not be opened further.

CAUTION: DO NOT over-open

the gate. Serious damage to the

gate stem and sealing surfaces

can result.

CLOSING – To close this slide

gate turn the handwheel in the

direction opposite of the “Open”

indicator until the stop nut on the

stem is 1/8" to 1/16" from the

top of the lift (see installation

instructions). When the top of

the stem is equal in height to the

bottom/ zero height indicator,

the gate is considered to be

FULL CLOSED and should not be

closed further. Should the gate

or stop nut require adjustment,

refer to the appropriate section

of the Installation, Operation, and

Maintenance Manual or call us

before any adjustments are made.

CAUTION: DO NOT attempt

to adjust the position of the stop

nut to achieve additional closing

stem travel without understanding

the function of the stem, stop nut

and gate closing system. Serious

damage to the gate stem and

sealing surfaces can result.

Manual Hand-Crank

OPENING – To open this gate

observe the direction of rotation

noted on the lift housing. Crank in

the direction of opening. If the gate

has been closed for an extended

period the gate may be difficult to

“unseat.” If several attempts at

turning the wheel to crack the gate

open have no result, apply heavy

pressure and wait for a period of

time. Allow the pressure in the

stem to unseat the gate. Continue

to turn the handcrank until the

desired gate position has been

achieved.

CAUTION: DO NOT over-open

the gate. Serious damage to the

gate stem guides and gate can

result. Do not use excessive

force.

CLOSING – To close this gate

turn the crank in the direction

opposite of the Open indicator

until the stop nut on the stem is

1/8" to 1/16" from the top of the

lift (see installation instructions).

After the gate has been closed as

noted on the indicator, the gate is

considered to be FULL CLOSED.

Then reverse the rotation of the

crank and relieve the pressure on

the stem and lift. Should the gate

or actuator require adjustment,

refer to the appropriate section

of the Installation, Operation, and

Maintenance Manual or call us

before any adjustments are made.

CAUTION: DO NOT attempt

to adjust the position of the stop

nut to achieve additional closing

stem travel. Serious damage to

the gate stem guide and gate can

result.

NOTE: For electrically or

hydraulically operated gates

please refer to manufacturer

Operation and Maintenance

Manuals.

OPERATION

MAINTENANCE AND LUBRICATION

HG561 FABRICATED SLIDE GATE

Maintenance

General Information

Occasional adjustment and

lubrication of Hydro Gate slide gate

components will be required. The

frequency will depend upon how

often the gate is used, location,

and operating conditions. Periodic

inspection, adjusting, and cleaning

are recommended as conditions at

the site permit.

Lift and Stem Maintenance

Maintenance of the threaded

operating portion of the gate stem

is critical and should be performed

as frequently as the operating

environment requires.

IMPORTANT: Failure to maintain

stem thread lubrication causes

operating difficulties and

premature failure of the lift nut

and stem threads.

Recommended inspection

frequency and procedures are

listed on the maintenance

schedule:

• Initial inspection at the time of

installation and again at the date

of commissioning.

A “cycle” of gate operation is

operation of the gate slide from

closed to open to closed position.

At each inspection, verify the

following items:

• Inspect the stem threads and

lift nut threads for wear and verify

the trueness and dimension of the

thread form. See wear checking

procedure.

• Check the amount and condition

(diary and day) of lubricant

remaining and add if necessary.

• Relubricate if necessary –

threads should be cleaned and

relubricated with fresh lubricant.

More severe conditions or

operating modes require a slightly

different schedule of inspection

and service. For example:

Modulating gates with electric

motor operators may make position

changes several times a day but

seldom go full stroke. There is a

portion of the stem that gets a

lot of use. These stems should

be inspected at least weekly. The

lubricant on the stem threads

should be monitored closely.

As the lubricant is depleted and

becomes contaminated, it should

be cleaned and replenished.

When excess dried grease or other

foreign material is carried into the

threads of the lift nut, extremely

hard operation will result. If serious

binding occurs, the only way to

correct it is to remove the threaded

stem from the lift nut and clean

the thread interior. If this foreign

material is not cleaned from the

interior threads of the lift nut,

heavy pulls on the handcrank or

seizure will result.

Stem threads may be cleaned with

solvent, rags, and brushes. Run

the gate open. While in the process

of opening (running the stem out

above the lift nut), clean off the

old grease. Inspect the threads

for roughness. If the threads

are rough, they may be filed and

polished. Be careful to keep filings

and grit out of the lift nut. Rough

stem threads accelerate the wear

of the lift nut threads.

Relubricate stem threads by

brushing or smearing grease

onto/into the threads as the

gate is closing (the stem is going

into the lift). This puts fresh

lubricant into the lift nut and

carries out the old contaminated

grease. It is recommended that

the contaminated grease be

cleaned from the stem as it exits

underneath the lift where the

stem is accessible from below.

Replenish grease on the underside

stem.

The recommended stem thread

lubricant is Schaeffer’s 238 ultra-

supreme.

Recommended for potable water

is a vegetable-based lubricant,

Shaeffer’s (XXXXXX).

Lifts may be furnished with a

stem lubricator Zerk Fitting which

is located in the “stem cover

adapter” to facilitate lubrication

of stem threads with pressure

greasing equipment. To be

effective, lubricant should be

injected while the stem is moving

through the lift.

Manual crank lifts have sealed

thrust bearing and do not require

lubrication.

Exercise of infrequently operated

lifts and gates is recommended.

A Semi-annual (every 6 months)

exercise will ensure the gate

is operable when needed and

the lubrication condition will be

maintained.

HG561 FABRICATED SLIDE GATE

Maintenance

Removal of the stem nuts for

thread inspection or check with

the wear checking procedure of

frequently modulated gates is

recommended.

Lubrication Equivalents

We consider any of the following

greases/lubricants to be acceptable:

• Fiske Brothers “Lubriplate” No.

630 AAA or AA

• Sta-Lube “Sta-Lube” No. 3121

• Conoco “All Purpose Superlube”

• Texaco “Multi Fak Heavy Duty”

No. 2

• Shell Gadus Grease (formerly

known as Alvania)

• Mobil “Mobilux EP2"

• BP Energrease LS 2

Replacement or spare nuts

can be ordered from us. Spare

parts are usually not needed or

recommended, because they are

readily available on short notice

We recommend the following pipe

thread sealants with Teflon:

• La-Co Slic-Tite Paste

• Dayton Pipe Thread Sealant with

Teflon

• McMaster-Carr Pipe Thread

Sealant with Teflon

• Any other commercially available

pipe thread sealants containing

Teflon

from us. In those cases where

equipment operation or downtime

is critical and the gate is operated

extremely often, a spare lift nut

may be pertinent to

have on hand.

For potable water treatment plants,

we recommends using a vegetable-

based lubricant such as:

• Lubriplate Super FML-2

• Rocol Foodlube Multi-Paste

(European product)

• Petro-Canada Purity-FG

Activity Frequency Lubricant

General Cleaning and Inspection As often as conditions require or

permit, or every 6 months.

N/A

Stem Thread and Lift Nut Wafer

Inspection

Initial inspection after 10 cycles.

Subsequent inspection after 25

cycles. Operational inspection after

each 50 cycles, or every 6 months.

N/A

Stem Thread Lubricant and Cleaning

Inspection

Every 3 months, quarterly, or 6

months. Clean grease if dried or

contains foreign material every 6

months. More frequent intervals

required for modulating duty.

Schaeffer's 238 Ultra-Supreme

TABLE 2. Maintenance Schedule and Lurbication Summary –HG561 Fabricated Slide Gates and Manual Lifts

LEAKAGE

HG561 FABRICATED SLIDE GATE

Leakage / Troubleshooting

The most frequent cause of excess

leakage through a newly installed

gate is improper installation and/or

failure to make final adjustments

to the gate before operation.

When you encounter this problem,

first verify that the Hydro Gate

installation instructions have been

carefully followed and that final

adjustments and greasing have

been accomplished. If not, then

follow step-by-step the adjustment

procedures as outlined in the

appropriate instructions.

Another important check is

to ensure the gates were not

disassembled for installation. The

outside of our installation booklet

states, “DO NOT DISASSEMBLE

GATE FOR INSTALLATION”. This

is repeated in the text of this

Installation, Operation, and

Maintenance manual at several

critical locations. Occasionally,

we still find that gates are

disassembled for easier handling,

painting, etc. When it is absolutely

necessary to partially disassemble

a gate or remove the slide to

facilitate installation, use extreme

care in handling the parts,

particularly the frame. As pointed

out above and in our installation

instructions, the amount of

leakage through the gate is highly

dependent upon the quality of the

installation.

CAUTION: Without the slide

in place, the frame is very fragile.

We cannot be responsible for

performance problems caused by

rough handling and damage to

gate parts.

AWWA C561 standard for

fabricated slide gates for seating

and unseating head is 0.1 gallons

per minute per foot of sealing

perimeter. A correctly installed

and adjusted HG561 Fabricated

Stainless Steel Gate are designed

to meet or exceed the allowable

AWWA leakage rate.

Troubleshooting Tips

Most fabricated slide gates depend

on water pressure with a slight

deflection of the gate slide to seal.

Proper installation and cleaning of

seating faces are still necessary

for the gate to be as watertight as

possible.

Excessive Localized Leakage

Check by opening the gate slide

to its FULL UP position. Use thin

wire, string, or straight edge to

check the gate frame. Stretch

the wire along each side. If there

is significant (1/32" or more)

variation in the seating face,

excess leakage will result in

those locations where warpage

has occurred. Also, stretch the

wire corner-to-corner across the

opening. If the strings do not touch

at the center, then one corner, or

the other, has been pulled back

considerably from the plane. To

repair this faulty installation, it is

necessary to loosen bolts, push

the frame out as required and align

it before tightening or regrouting.

Dirty Seating Faces

Excess leakage can also be caused

by foreign material on seating

faces of the gate frame or slide.

Check for drops of paint, cement

runs on seating faces, or other

construction grime. To correct,

remove foreign material from the

perimeter of the seating faces on

both slide and frame, and reseat

the gate.

Excessive Leakage near Top of

Slide

If leakage occurs primarily at

the top near the stem, there is

probably excess compression in

the stem, which is pulling the

gate slide from its frame. Check

by turning the handwheel or

handcrank in the direction to open

the gate. When excess pressure

on the stem is removed, the slide

will spring back into position.

Reset the top nut, and refer to

Electrical Actuator Operating and

Maintenance Manual to adjust

torque and limit switches as

needed.

Excessive Leakage near Top of

Slide, Frame Not Warped

If leakage occurs primarily at the

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