20160216 Ver 1 _Minimum Flow Plan _20171101

Burdette, Jennifer a
From: Tarver, Fred
Sent: Friday, November 03, 2017 1:44 PM
To: Mark Landis; Burdette, Jennifer a
Cc: Laura Shearin-Feimster; Kevin Lugo ([e-mail])
Subject: RE: [External] FW: Hope Mills Dam - Certification No. 4066
Thanks for the quick response. That answers my questions.
Fred
Fred R Tarver III
Instream Flow Program Supervisor
Department of Environmental Quality
919-707-9029 office
[e-mail]
Division of Water Resources
1611 Mail Service Center
Raleigh NC 27699-1611
Email correspondence to & from this address is subject to the N. C. Public Records Law & may be disclosed to third
parties!
From: Mark Landis [mailto:[e-mail]]
Sent: Wednesday, November 01, 2017 1:27 PM
To: Tarver, Fred <[e-mail]>; Burdette, Jennifer a <[e-mail]>
Cc: Laura Shearin-Feimster <[e-mail]>; Kevin Lugo ([e-mail]) <[e-mail]>
Subject: [External] FW: Hope Mills Dam - Certification No. 4066
CAUTION: External email. Do not click links or open attachments unless verified. Send all suspicious email as an attachment to
report. spamknc.gov.
Jennifer and Fred,
I received these questions from Kevin Lugo and he asked me to respond directly to you. Here is a revised version to
remove the 20% reduction and answers to questions are below in red. If you have questions about the table on min release
please call Laura Shearin-Feimster or me at 336 274-9456. Thank you
Mark
From previous email below:
On first blush, I wonder why—based on the labyrinth diagram—they are maintaining minimum flow with a bottom gate?
Why not over top of the weir/dam? Flows are maintained over the spillway once the reservoir fills. Was there some
rationale for this approach? We kept the same overflow as the previous dam (I seem to recall that there was some
discussion in the past about the elevation that the new impoundment would be held at would be lower than previous, so
perhaps the crest is higher than the new elevation? I do see that the diagram lists the crest at 105 ft and normal pool

elevation is 104 ft.) no — the crest in the lowest weir is 104 — normal pool will be higher than that for base flow conditions
except in extreme drought conditions
(The document states the following: "If the reservoir level drops below El 104.2 ft with the gate closed, less than 38 cfs is
flowing over the spillway." Why would the pond level drop with the gate closed unless there's a leak or some sort of
offstream usage? Only in Drought conditions There should be some amount of flow over the crest unless the inflow goes
to zero, i.e., inflow—outflow.) During first fill we will need to release min flow, here is when we use the gate - When the
reservoir water level is being raised up to normal pool, such as during the first filling or if the water level was lowered for
maintenance purposes, the gate will be operated so that a minimum of 38 cfs is passing through the gate.
Providing downstream flows using the bottom gate gets very complicated when inflow roughly approximates or is less
than the gate opening.
The DWR letter from 2004 stated 38 cfs, or inflow, whichever is less. Therefore, the 20% reduction is not correct when
flows are less than 38 cfs, or drought condition as describe in the document. I assume the 20% reduction is somehow
related to the 20% 7Q10 SEPA minimum criteria, and if so, this is a misapplication. We can remove the 20% reduction
part and just say once the reservoir is filled, the inflow into the reservoir will be passed over the crest of the labyrinth or
something along those lines
If there are no offstream uses associated with the impoundment, then inflow should approximate outflow and easy to
maintain over the crest; however, if there are significant offstream uses that may impact outflow, then these uses need to
be curtailed in conjunction with a 3 -tiered release schedule, as spelled out in the dam safety rules. There are no water uses
from the reservoir other than recreation — ie no withdrawals
There could be a potential water quality issue with anoxic bottom water releases when the impoundment is stratified in the
summer.
Better a warm, top -water release with some DO than a cool, bottom -water release with no DO? We are not changing the
previous release mechanism which was the water flowing over the top over the weir for base flow and storm flow
I assume that Little Rockfish Creek is a warm -water system and that the DO is more beneficial than the cooler water.
Mark E. Landis, PG, PE / Principal
Schnabel ENGINEERING
Build Better. Together.
From: Laura Shearin-Feimster
Sent: Wednesday, November 1, 2017 9:25 AM
To: Mark Landis
Subject: RE: Hope Mills Dam - Certification No. 4066
Here's a revised version. I think it answers all his questions.
Laura
From: Kevin Lugo [mailto:klu og na,mbpce.com]
Sent: Tuesday, October 31, 2017 6:12 PM
To: Mark Landis
Subject: FW: Hope Mills Dam - Certification No. 4066
Importance: High
Mark,
Do you think you can help with a response to this? We submitted the minimum release plan as required by the permit.
Thanks,

Kevin
From: Burdette, Jennifer a[mailto:Jennifer.Burdette(aDncdenr.gov]
Sent: Tuesday, October 31, 2017 1:55 PM
To: Kevin Lugo <klu og kmbpce.com>
Subject: FW: Hope Mills Dam - Certification No. 4066
Kevin,
I asked Fred Tarver, the Division's Instream Flow Program Supervisor, to review the Hope Mills Minimum Flow
plan that you provided. Fred's comments are provided below. Please review these comments and respond.
Thanks,
Jennifer
Jennifer Burdette
401/Buffer Coordinator
Division of Water Resources - 401 & Buffer Permitting Branch
Department of Environmental Quality
919 807 6364 office
0ennifer.burdettea-ncdenr.gov
1617 Mail Service Center
Raleigh, NC 27699-1617
(Physical Address: 512 N. Salisbury St, Raleigh, NC 27604 - 9t" F1rArchdale Bldg – Room 942F)
Email correspondence to and from this address is subject to the
North Carolina Public Records Law and may be disclosed to third parties.
From: Tarver, Fred
Sent: Monday, October 30, 2017 5:22 PM
To: Burdette, Jennifer a<Jennifer.Burdette(aancdenr.gov>
Subject: RE: [External] Hope Mills Dam - Certification No. 4066
Jennifer,
On first blush, I wonder why—based on the labyrinth diagram—they are maintaining minimum flow with a bottom gate?
Why not over top of the weir/dam? Was there some rationale for this approach? (I seem to recall that there was some
discussion in the past about the elevation that the new impoundment would be held at would be lower than previous, so
perhaps the crest is higher than the new elevation? I do see that the diagram lists the crest at 105 ft and normal pool
elevation is 104 ft.)
(The document states the following: "If the reservoir level drops below El 104.2 ft with the gate closed, less than 38 cfs is
flowing over the spillway." Why would the pond level drop with the gate closed unless there's a leak or some sort of
offstream usage? There should be some amount of flow over the crest unless the inflow goes to zero, i.e.,
inflow—outflow.)
Providing downstream flows using the bottom gate gets very complicated when inflow roughly approximates or is less
than the gate opening.
The DWR letter from 2004 stated 38 cfs, or inflow, whichever is less. Therefore, the 20% reduction is not correct when
flows are less than 38 cfs, or drought condition as describe in the document. I assume the 20% reduction is somehow
related to the 20% 7Q10 SEPA minimum criteria, and if so, this is a misapplication.
If there are no offstream uses associated with the impoundment, then inflow should approximate outflow and easy to
maintain over the crest; however, if there are significant offstream uses that may impact outflow, then these uses need to
be curtailed in conjunction with a 3 -tiered release schedule, as spelled out in the dam safety rules.

There could be a potential water quality issue with anoxic bottom water releases when the impoundment is stratified in the
summer.
Better a warm, top -water release with some DO than a cool, bottom -water release with no DO?
I assume that Little Rockfish Creek is a warm -water system and that the DO is more beneficial than the cooler water.
Let me know if you wish to discuss further.
Fred
Fred R Tarver III
Instream Flow Program Supervisor
Department of Environmental Quality
919-707-9029 office
fred.tarverancdenr.aov
Division of Water Resources
1611 Mail Service Center
Raleigh NC 27699-1611
Email correspondence to & from this address is subject to the N. C. Public Records Law & may be disclosed to third
parties!
From: Burdette, Jennifer a
Sent: Friday, October 27, 2017 4:49 PM
To: Tarver, Fred <fred.tarverkncdenr.gov>
Subject: FW: [External] Hope Mills Dam - Certification No. 4066
Hi Fred,
I received the attached minimum release plan for Hope Mills Dam. Would you mind to please review and
provide comments?
Jennifer
Jennifer Burdette
401/Buffer Coordinator
Division of Water Resources - 401 & Buffer Permitting Branch
Department of Environmental Quality
919 807 6364 office
0ennifer.burdette(a)ncdenr.gov
1617 Mail Service Center
Raleigh, NC 27699-1617
(Physical Address: 512 N. Salisbury St, Raleigh, NC 27604 - 9t" F1rArchdale Bldg — Room 942F)
Email correspondence to and from this address is subject to the
North Carolina Public Records Law and may be disclosed to third parties.
From: Kevin Lugo [mailto:klu og gmbpce.com]
Sent: Tuesday, October 17, 2017 10:46 AM
To: Burdette, Jennifer a <Jennifer.Burdettegncdenr.gov>

Cc: Greer, Emily C CIV USARMY CESAW (US) <Emily.C.Greergusace.army.mil>
Subject: [External] Hope Mills Dam - Certification No. 4066
CAUTION: This email originated from outside of the organization. Do not click links or open attachments unless you verify that the
attachment and content are safe. Send all suspicious email as an attachment to report. spamknc.gov.
Jennifer,
I sent the minimum release plan to Emily Greer, USACE but realized I did not forward it to you. Just in case Emily has
not had a chance to forward it to you yet, please see attached 38cfs minimum release plan for approval. Note that the
slopes of the earthen embankment are staked with elevations to track the elevation of the lake while filling. Schnabel,
once we are permitted to impound by Dam Safety, intends to control how fast the lake impounds at approximately 1 foot a
day. It is estimated that it will take over 2 weeks for the lake to fill.
Since we are nearing completion of the project, I went on line to retrieve the certificate of completion and noticed that is
an older form with McCrory as governor. Is there a newer form or should I just edit it? We anticipate that the project will
be substantially complete this week once the piezometers are fully functional. Would it be acceptable to send you the
certificate based on substantial completion? There will be only minor items left, such as a few punchlist items, to be
completed and then an inspection by Dam Safety and approval to impound; estimated to be received 11/15.
Thank you,
Kevin
Kevin M. Lugo, PE, CCM
Vice President, Branch Manager
148P
3200 Beechleaf Court I Suite 910 1 Raleigh, NC 27604
866-845-8599 (toll free) 1 919-875-0124 (office) 1 919-673-7963 (cell)
www.mbpce.com I klu og @mbpce.com
The information contained in this electronic mail message and any attachments is
confidential information intended only for the use of the individual or entity named.
If the reader of this message is not the intended recipient, you are hereby notified
that any dissemination, distribution or copying of this communication is strictly
prohibited. If you have received this communication in error, please immediately
notify us by telephone at 800-898-9088 and delete this message. Thank you.

SCHNABEL ENGINEERING SOUTH, P.C.
Schnabel Greensboro,
Oak Branch Drive
eee nsboro, NC 27407
E N G I N E E R I N G T/ 336-274-9456
F/ 336-274-9486
MEMORANDUM
TO: Melissa Adams DATE: November 1, 2017
COMPANY: Town of Hope Mills SUBJECT: Minimum Release Plan
ADDRESS: 5770 Rockfish Road PROJECT Hope Mills Dam / 15821009
Hope Mills, NC 28348 NAME/NO.:
FROM: Laura Shearin-Feimster, PE CC:
Mark E. Landis, PG, PE
This minimum release plan will be included in the Operation and Maintenance Manual for Hope Mills Dam.
INTRODUCTION
The following minimum release plan was developed to address the requirement as defined in the 401 Water Quality
Certification with Additional Conditions Permit.
"The Division approves your plan to provide a minimum flow of 38 cfs. Prior to refilling the lake, a minimum water release
plan must be approved by the Division. The plan must include design specifications, details (i.e. low-level outlet gate's
size and location relative to the bottom of the lake), calculations to show that the release shall be achieved in the given
conditions and the method and frequency of monitoring the upstream staff gage and discharge. [I 5A NCAC 02B
.0506(b)(3)]"
DESCRIPTION OF THE SLUICE GATE SYSTEM
Located on the left side of the labyrinth is an 8 foot wide by 24.5 foot high wall extension. This wall extension has a 4 foot
by 4 foot sluice gate. The sluice gate is operated by a crank operated floor stand located on top of the wall. The sluice
gate has a base elevation of 86 feet, which is even with the labyrinth slab. The capacity of the gate at normal pool
elevation of 104 ft is 308 cubic feet per second (cfs) when fully open.
The gate opening flow calculations, the design drawings, and the gate manufacture's instruction manual are attached.
NORMAL AND LOW FLOW CONDITIONS
Hope Mills Lake is operated under an inflow equals outflow condition when the reservoir is filled. Water is not pumped out
or redirected from the lake to an offsite location. Therefore, under both normal and low flow conditions, the flow rate of
Little Rockfish Creek is essentially unaffected by the dam operations.
If the reservoir level has been lowered by the Town of Hope Mills Staff below elevation 104.2, such as for maintenance
purposes, the procedure outlined in the following section "Operations Under Reservoir Filling" should be followed.
SENT VIA: ❑ First Class Mail ❑ Overnight Service ❑ Email ❑ Other
G:\2015\GREENSBORO\15821009 00 HOPE MILLS DAM\03-SE PRO DUCTS\03-REPORTS\O&M\REVISED MINIMUM RELEASE PLAN.DOCX

Town of Hope Mills
Restoration of Hope Mills Dam
OPERATIONS UNDER RESERVOIR FILLING
When the reservoir water level is being raised up to normal pool, such as during the first filling or if the water level was
lowered for maintenance purposes, the gate will be operated so that a minimum of 38 cfs is passing through the gate. The
table below has the recommended minimum gate opening based on the reservoir level. While the reservoir is filling, the
reservoir level should be monitored daily and the gate adjusted as necessary. The filling of the reservoir should not
exceed one foot per day.
SIGNED
Minimum Gate Opening - Normal Conditions
Minimum
Gate
Opening (ft)
Top of
Gate
Elevation
(ft)
Reservoir
Height
Above Slab
(ft)
Reservoir
Elevation
(ft)
2
92
2.0
88.0
1.5
91.5
2.5
88.5
1.4
91.4
2.7
88.7
1.3
91.3
3.0
89.0
1.2
91.2
3.3
89.3
1.1
91.1
3.8
89.8
1
91
4.4
90.4
0.9
90.9
5.3
91.3
0.8
90.8
6.5
92.5
0.7
90.7
8.3
94.3
0.6
90.6
11.1
97.1
0.5
90.5
15.8
101.8
0.47
90.47
17.9
103.9
Laura E. Shearin-Feimster, PE, ENV SP
Project 15821009 / November 1, 2017 Page 2 Schnabel Engineering South, P.C.

Project: Hope Mills Dam (15821009) Schnabel
Subject: Discharge Monitoring Rating Curve - Minimum Gate Openings
Date 9/26/2017 10 ENG f NEE R ING
Filename: G:\2015\Greensboro\15821009_00_Hope_Mills_Dam\03-SE Prod ucts\03-Reports\O&M\[Reservoir Filling Calculation.xlsx]Normal Conditions
By LES Checked LWC
Data Source: Dimensions and elevations from Design Drawings
Notes: Target minimum discharge is 38 cfs during reservoir filling
All Elevations reference the NAVD 88
Under Normal Flow Conditions
Minimum Release is 38cfs
Innuts
Gate Invert EI (Closed) =
Top of Gate EI (Closed) =
Target Minimum Flow =
Acceleration of Gravity =
Calculations
Gate
Opening
Area (ft)
Total Head
(ft)
8
1.0
6
1.7
5.6
2.0
5.2
2.3
4.8
2.7
4.4
3.2
4
3.9
3.6
4.8
3.2
6.1
2.8
7.9
2.4
10.8
2
15.6
1.88
17.6
86 ft
90 ft
38 cfs
32.2 ft/s2
Results
Orifice Coefficient = 0.6
Gate Width = 4 ft
Gate Height = 4 ft
Minimum Gate
Opening (ft)
Top of Gate
Elevation (ft)
ReservoirReservoir
Height Above
Slab (ft)
Elevation (ft)
2
92
2.0
88.0
1.5
91.5
2.5
88.5
1.4
91.4
2.7
88.7
1.3
91.3
3.0
89.0
1.2
91.2
3.3
89.3
1.1
91.1
3.8
89.8
1
91
4.4
90.4
0.9
90.9
5.3
91.3
0.8
90.8
6.5
92.5
0.7
90.7
8.3
94.3
0.6
90.6
11.1
97.1
0.5
90.5
15.8
101.8
0.47
90.47
17.9
103.9

CREST CUT-OFF WALL
EL 108,0
`r F2.-6.
I T-- F---
LABYRINTH WEIR PROFILE AT
CE HTERLIHE OF EMBANKMENT.
TOP OF WALL EL 105.0
CREST CUT-OFF WALL
EL 108.0 1
f
2'-6'
TOP OF $LAB
EL 86JD
r11 LABYRINTH SPILLWAY SECTION
0 SCRLE' ,8'•, b'
o s is
". 30'-6'
2 LABYRINTH SPILLWAY SECTION
TOP OF SLAB
EL 86.0
Q Q U)
D a z
�No 0
J
Lu ()
aw=W
=oma U]
1,
0LLz
Zoe Q
oo� �
OFa J
ry O d
L [n
.r_
V
LL v!1 O
Q �
D rA N
Ul z
U
�. U
N
6
PROJECT: 158210D9.00
DATE: MAY 2016
DRAWING NO.
S-05
SHEET
26 OF 53

REVISED 8-27-15
00000
Hyd re
n & & '�"� Gaite
Installation, Operation, &
Maintenance Manual
DO NOT DISASSEMBLE GATE FOR INSTALLATION
Cast Iron Slide Gates
G1000
12000 E. 47"' Ave., Suite 200 • Denver • Colorado • 80239 • 1-800-678-8228 • FAX [phone]
www.hydrogate.com

Ntt Hydro Gate
TABLE OF CONTENTS
CAST IRON SLIDE GATES
Cast Iron Slide Gates
Cautionary Statement.............................................................................. i
Foreword................................................................................................ ii
INSTALLATION
Safety Precautions.............................................................
1
Things To Do and Not To Do during Installation ........................
2
Wall Thimble Installation......................................................
3-4
Installation of Gate on Wall Thimble .......................................
5-6
Correcting and Compensating for a Warped Thimble .................
7
Installation of Flush Bottom Closure Gates ...............................
8
Installation of Flat or Flange Back Gates on Concrete without a Thimble ...
9-10
Gate Stem and Guides Installation .........................................
11-12
Lift Installation and Adjustment of Stem Guides ........................
13-15
Cleaning and Final Adjustment of Gate ...................................
16
Wedge Adjustment............................................................
16-20
Flush Bottom Closure Adjustment ..........................................
20
Manual Lifts, Parts, and Assemblies ........................................
21
OPERATION
General Operation Information .............................................. 22
Cast Iron Slide Gate Operation Procedures .............................. 22-23
MAINTENANCE
Field Cleaning and Painting ................................................... 24
Maintenance and Lubrication ................................................ 25-26
Maintenance Schedule and Lubrication Summary ....................... 27
List of Lubricants................................................................ 28
Leakage............................................................................ 29
Troubleshooting Tips........................................................... 30-32
Long -Term Storage Instructions ............................................. 33
Warranty.......................................................................... 34
PARTS
Exploded View and Parts list.................................................35-37
SpareParts...................................................................... 38
Hydro Gate Installation, Operations and Maintenance

Hydro Gate
Cast Iron Slide Gates
CAUTIONARY STATEMENT FOR INSTALLATION, OPERATION, &
MAINTENANCE MANUAL
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
Hydro Gate, this manual will be sufficient 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 specific project, contact Hydro Gate's headquarters.
PRECISE AND ACCURATE INSTALLATION IS CRITICAL TO
SATISFACTORY OPERATION. HYDRO GATE ASSUMES 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 HYDRO GATE'S COLORADO FACILITY. HYDRO
GATE EXPRESSLY DISCLAIMS 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.
Hydro Gate Installation, Operations and Maintenance
-i-

J Hydro Gate
FOREWORD
Cast Iron Slide Gates
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 Cast Iron Slide
Gates and their component parts.
The gate, lift, and accessories were accurately machined, assembled, adjusted, and inspected before
leaving the Hydro Gate Corporation 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 equipment will not be installed immediately, consult the long-term storage instructions following.
Installation Note
Do not disassemble the gate or lift for installation.
Warranty Note
Installation and/or operation of the gate lift and stem without proper lubrication will void the equipment
warranty. Thorough cleaning of the stem, seating faces, and wedging surfaces is required before gate
operation. Details are described in the appropriate sections of this manual.
Notes
Spare Parts — Hydro Gate does not recommend the stocking of spare parts. If spare parts are required
see page 38. Replacement parts are readily available for worn or broken parts. Contact
Hydro Gate or our representative in your area.
Special Tools — Special tools are not required to operate and/or maintain the equipment supplied by
Hydro Gate on this project.
Price List — Prices for individual parts and/or assemblies may be obtained from Hydro Gate at the
time that they are needed.
Disassembly — Hydro Gate does 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 Hydro Gate's Field Service
Department at [phone].
Hydro Gate Installation, Operations and Maintenance
-ii-

Hydro Gate
INSTALLATION
Safety Precautions
Cast Iron Slide Gates
To help ensure your workers' safety, Hydro Gate recommends 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 Cast Iron Slide
Gates.
• 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 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 Operation and Maintenance
Manual.
• Contact your Hydro Gate representative with any questions you may have regarding safety in
installing, operating, and handling Hydro Gate products.
1
Hydro Gate Installation, Operations and Maintenance

Hydro Gats
------------------------------------------------------------------------------ Cast Iron Slide Gates
Things To Do and Not To Do during Installation of This Gate
To properly install this gate, Hydro Gate recommends that personnel study these instructions and
installation drawings and follow the installation directions carefully. This gate is precision machined, 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.
Some DO'S and DON'TS to ensure proper gate installation.
✓ DO — Read and follow the Installation instructions and drawings in this Manual.
✓ DO — 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 reported in writing within 30 days of shipment.
✓ DO — Store gates evenly on planks or timbers. Even the heaviest castings are subject to
permanent warpage if unevenly blocked during storage.
✓ DO — Support full length of stems and protect threads during storage and handling.
✓ DO — Accurately locate and brace embedded items during placement of concrete.
✓ DO — Contact your Hydro Gate representative with questions regarding this gate. Hydro Gate and
its related companies have 100 years combined experience in the water control industry.
✓ DON'T — Stack gates without heavy wood blocking between gates.
✓ DON'T — Disassemble the gates for installation.
✓ DON'T — Allow excess concrete to overlap gate thimble or frame.
✓ DON'T — Tighten nuts for studs or anchors unevenly, or try to pull a gate frame tightly against an
uneven wall surface. This, in most cases, will cause excessive leakage.
✓ DON'T — Operate gates with concrete and debris on them.
✓ DON'T — Operate gate stems dry (without grease).
2
Hydro Gate Installation, Operations and Maintenance

Hydro Gate
Wall Thimble Installation
Cast Iron Slide Gates
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 machined 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.
3. Studs furnished for attaching of 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 (Figure 1).
Installation Note
Use 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.
3
Hydro Gate Installation, Operations and Maintenance

Hydro Gate
Cast Iron Slide Gates
Figure 1- Front View of Thimble Showing Bracing
Block out for top anchors or
place J -bolt anchors in form
for concrete pour.
See installation drawing for
location.
Provide timber blocking
as required to support
thimble during pouring.
0 0 0 0 0 0 0 —0-0-1
0 I ISI 111 N If I 10
0 I t IMII I IHE 10
0 IF III V 1 IH1 AI 0
0 II i II 1 II N I II 0
Plumb thimble in forms
using top and bottom.
4
Hydro Gate Installation, Operations and Maintenance

Hydro Gats
------------------------------------------------------------------------------ Cast Iron Slide Gates
Installation of Gate on Wall Thimble
1. Clean machined face with scrapers and wire brush so that no sand, concrete, dirt, or foreign material
is present (Figure 2).
2. Check flatness and plumb of thimble face to verify that it did not move or shift during concrete pour.
Flatness must be within 1/64 inch of true flat plane. The thimble should be plumb within 1/8 inch.
Use good quality plumb level, or plumb lines, at each vertical side. Both sides should be plumb or
parallel to each other within 1/32 inch over the total height.
3. After verifying thimble flatness and alignment, install thimble stud bolts.
4. Check the installation drawings for use of anchor bolts to stabilize the upper frame guides or
extensions. If shown on the installation drawing, install a nut on these anchors and run on as far as
possible before installing the gate.
5. Trowel a thin layer (1/16 inch to 1/8 inch thick) of mastic on the face of the thimble or two '/2 inch
diameter beads of mastic from a caulking gun; one bead midway between the inner edge of the face
(opening) and the row of studs and the other bead just outside the row of studs. Place a circular bead
around each stud. These beads should be of size and placement so they will flow out and
substantially cover or wet the flange joint. Trowelable grades of asphalt roof cement, or polyurethane
sealants (Sika -Flex 1-A or equivalents), work well as mastic.
6. Although Hydro Gate does not recommend using rubber gaskets in place of mastic, they may be
used at the discretion of the owner or consulting engineer. They should be no more than 1/8 inch
thick and the thimble must be flat within the 1/32 inch total maximum warping allowed. Use of thicker
gaskets may result in a spongy foundation for the gate or blowout under high unseating heads.
7. Tighten all stud nuts uniformly. The torque table in the Wedge Adjustment section of this manual is
only a guide. It is not mandatory that nuts be tightened precisely to these values. The basic rule is
wrench tighten with the common available wrench length.
Repeated tightening will be required to squeeze mastic to a thin layer for metal -to -metal contact.
Refer to tightening sequence diagram. Repeat tightening until all bolts are holding torque.
8. Use caution when mounting gates on nonmachined steel structures, round flanges, or existing
thimbles. The rules of flatness discussed above apply. Severe distortion of the gate and subsequent
excessive leakage results when torque tightening gate mounted on uneven/non-flat surfaces. Do not
torque tighten a gate to an uneven non -flat surface.
5
Hydro Gate Installation, Operations and Maintenance

Hydro Gate
Cast Iron Slide Gates
Figure 2 - Front Cross Section of Thimble Showing Machined Front Face
Tapped
in —'
Hole
Concrete or
Grout.
clean
Front
Machine Face
of Thimble.
"F" Wall Thimble
Typical Thimble Installation
6
Hydro Gate Installation, Operations and Maintenance

X01 Hydro Gats
'`' Cast Iron Slide Gates
Correcting and Compensating for a Warped Thimble
If the vertical faces are out of parallel more than 1/32 inch, the thimble is warped or twisted excessively
and the gate may exhibit sealing problems. Warping can be corrected in one of the following ways:
1. Remove thimble from concrete and try again. This requires substantial demolition and risks damage
to the structure and thimble.
2. The preferred correction involves mounting the gate on the thimble with shims between gate and
thimble flanges to restore gate seat faces to a good contacting condition. The resulting gap between
gate and thimble flange can be sealed with mastic such as polyurethane seal -like Sika Flex 1-A.
There is a limit to how wide a gap the chosen mastic will seal. Consult the mastic supplier for gap
limit and cure times. Sika Flex 1-A with Sika Flex primer claims to bridge and seal up to 1/2 -inch
gaps. Sika Flex 1-A requires a 1 -week cure for water immersion; Sika Flex -2C NS/S1 requires a 3 -
day cure. Hydro Gate recommends not exceeding 1/4 -inch gap with polyurethane considering
uncertainties such as water pressure.
When the twist or warp exceeds 1/4 inch or operating heads are high (more than 20 feet of water),
Hydro Gate recommends that the gap be filled with injectable epoxy to both form a watertight joint and
provide a solid mounting for the gate. This work is best performed by an Adhesive and Sealing
Contractor who can dam up the gap and inject the material.
The recommended steps to shim a gate frame are as follows:
A. Dry mount the gate (i.e. without mastic.) If the gate has been wet -mounted with mastic, remove
the gate and clean off all mastic, then dry-mount the gate. Do not tighten stud bolts.
B. Determine where and what thickness shims are needed between the frame and thimble, which will
produce gate seat contact that excludes a .004 -inch feeler gage.
Shims may be stainless steel washers placed on stud bolts between the gate and thimble flange
or "C" -shaped shims cut from stainless shim stock. Place the "C" straddling the stud bolts.
C. Tighten all stud nuts, then verify that the gate seat is contacting within .004 inch all around the
opening.
D. Remove the gate, keeping track of what shims go where.
E. Apply a thick layer of mastic on the thimble or gate flange sufficient to seal the gap resulting from
the shimming action or prepare for epoxy injection by Adhesive/Sealing Contractor.
3. If the thimble face is flat but is out of plumb, or racked, consult Hydro Gate's Engineering Department
for suggestions. The axis of movement of the slide must be parallel to the axis of the stem within
certain limits, depending on the gate size. Hydro Gate's Engineering Department can determine
these limits for the specific installation and offer suggestions.
7
Hydro Gate Installation, Operations and Maintenance

Hydro Gats
------------------------------------------------------------------------------ Cast Iron Slide Gates
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 (Figure 3). 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.
Figure 3 — Bottom View of Gate Slide and Invert Interface
Rem
Retai
Flush
Seal
Beveled Bottom
Slide
Frame
8
Hydro Gate Installation, Operations and Maintenance

Hydro Gate
Cast Iron Slide Gates
Installation of Flat or Flange Back Gates on Concrete without a Thimble
Secure all anchor bolts in proper position in the forms. For proper size, length, projection and
spacing, see Hydro Gate installation drawing.
Installation Note
An upper anchor is often required for supporting the upper gate frame.
2. Two nuts and washers are provided per bolt. Grout space must be left for adjustment of the back nut
on the anchor bolt as shown in Figures 4 and 5. The anchor bolt projection shown on the installation
drawing provides for the suggested thickness of the grout shown.
3. Pour concrete and strip forms.
4. Coat threads with anti -seize lubricant. Place one nut on each anchor bolt and adjust them to establish
a true flat and vertical plane. Starting with the nuts on the corner anchors, taut string lines (horizontal)
and plumb lines (vertical) to bring all nuts around the opening to a flat vertical plane. Place the
completely assembled gate into position on the anchor bolts, straightening them as required. Install a
second nut and washer on each anchor bolt. Bring the front nuts into light uniform contact with the
gate frame, aligning the gate as required. Check for firm contact at the back of the nut, then
uniformly tighten all of the front nuts around the opening. Check for proper seating tolerance with a
.004 -inch feeler gauge.
Installation Note
To ensure the gate frame has not been distorted during this process, attempt to insert a .004 -inch feeler
gauge between the seating faces around the entire perimeter of the opening. If the gauge can be
inserted between the faces, then adjust the anchor bolt nuts to eliminate the gap.
5. Carefully grout in the gate, using 5 -star grout, or equal.
6. After the grout has set, make certain there are no voids between the gate frame and the concrete.
Because of possible shrinkage of certain types of grout, it may be necessary to loosen the gate and
apply a sealing compound between the gate seat and the wall.
7. Lubricate all nuts and anchor bolts with anti -seize lubricant and tighten uniformly.
Installation Note
Do not warp the gate to conform to any uneven surfaces.
8. To complete the gate assembly, install nuts on the anchor bolts located on the upper frame extension.
Bring both the front and back nuts in firm contact with frame. Tighten both without distorting the
frame.
9
Hydro Gate Installation, Operations and Maintenance

Hydro Gats
------------------------------------------------------------------------------ Cast Iron Slide Gates
Figure 4 - Top View of Anchor Bolt Mounting with Flanged Back Gate
Concrete
Grout
e
I Anchor/J Bolt
to include locking nut
Frame and tightening nut.
Figure 5 - Top View of Anchor Bolt Mounting with Flat Back Gate
Concrete
rramc Anchor/J Bolt
to include locking nut
and tightening nut.
10
Hydro Gate Installation, Operations and Maintenance

X01 Hydro Gate
Gate Stem and Guides Installation
Cast Iron Slide Gates
1. Place the anchor 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 inch per each 10 feet of distance.
2. Provide opening with adequate clearance in the lift platform for the gate stem.
3. Pour concrete and strip forms.
4. Install stem guide brackets on anchors, but do not tighten nuts; leaving them loose so the bracket can
be moved for later alignment. Loosen all assembly bolts holding the collars to the bracket. Stem
guide collars may be 1- or 2 -piece construction. Place 1 -piece collars on each succeeding stem
section as it is installed. After each collar is installed, re -bolt it to its bracket, but do not tighten.
5. 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.
Installation Note
Exercise care when handling and installing threaded stems; nicks or burrs will damage lift nut threads.
6. Insert the stem block into the gate slide pocket.
7. Stems may be in more than one piece to facilitate shipment and installation. If two or more pieces are
furnished for an installation, they must be installed in their proper order from bottom to top to place
splices in correct location so that they will not interfere with the stem guides when the gate is opened
or closed. Measure the stem section lengths and install.
8. 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 (Figure 6).
Installation 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 as the turning motion is between the block and the stem.)
9. Place all of the succeeding stem sections. Double-check the installation drawings to ensure that one-
piece stem guide collars are in place. Join together with splices as provided (Figure 7).
Safety 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.
10. Immediately before lowering the lift over the threaded portion of the stem, remove the protective
wrapping from the stem and thoroughly clean off all foreign material.
11. Lubricate stem threads with recommended lubricants. Do not leave lubricated stem exposed to
contamination before completing the installation.
11
Hydro Gate Installation, Operations and Maintenance

Hydro Gate
Figure 6 - Stem Block and Key
Figure 7 - Stem with Splice
Key
Stem
block
Stem
Cast Iron Slide Gates
12
Hydro Gate Installation, Operations and Maintenance

Hydro Gats
------------------------------------------------------------------------------ Cast Iron Slide Gates
Lift Installation and Adjustment of Stem Guides
1. Remove protective covering or plugs from the gate -lifting device. Clean the interior threads of the nut.
Installation Note
Foreign material in the nut threads may cause damage and make the gate harder to operate. Each
threaded nut should be carefully swabbed out even if it appears to be clean.
2. 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.
Warranty Note
Operation of the gate assembly without proper lubrication of the stem will void the equipment warranty.
3. 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 anchor bolts.
Installation Note
When all parts are cleaned, the threaded lift nut will turn onto the threaded stem with very little effort.
4. The gate is shipped with a steel clip or clips attached to the frame at the top corner of the slide
(Figure 8), which held the slide closed during shipment. It should now be removed and discarded.
Installation Note
Do not attempt to operate gate without removing shipping clips.
5. Using shims, double nuts on anchors, 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 inch per 10 feet of distance. Tighten nuts on the anchors uniformly.
6. 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.
7. 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.
13
Hydro Gate Installation, Operations and Maintenance

Hydro Gats
------------------------------------------------------------------------------ Cast Iron Slide Gates
8. Grout under the lift (if required). After the grout has set, tighten the anchor bolts uniformly.
Installation 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 recheck the projection of the anchors or studs
across the top of the gate opening. Excess bolt projection will damage the top corrosion -resistant metal
seating face on the slide when it is opened.
9. Turn the lift crank or handwheel to open the gate, until the gate slide is pulled from its wedges. The
stem is now in tension. Check the stem to be certain it is straight. Tighten the nuts on the anchors
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.
10. 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 Hydro Gate for ways to correct or compensate for this condition.
11. Lower the gate to fully closed position and check the wedges and the seating faces as described
below. Run the stop nut down on top of the projecting threaded stem until it contacts the top of the lift
nut or stem cover flange. Back the nut up until 1/8 -inch gap appears between the lift and the stop nut
to allow complete gate closure as sliding and bearing surfaces wear in.
12. Tighten the setscrews through the stop nut to hold it in place (Figure 9).
13. Install the stem cover, indicator, etc., as required.
Figure 8 - Gate Frame and Slide with Shipping Clips
Wed!
able
Slide
14
Hydro Gate Installation, Operations and Maintenance

Hydro Gate
Figure 9 - Handwheel and Stopnut
ORDER ID T
Figure 9 - Removable CRANK
2 IN,
OPEF
RANI
REVOLVING MAN[
PEDESTAL
Cast Iron Slide Gates
STOP NUT
HANDINHEEL
DVER ADAPTER
D GEARBOX
UT
N PEDESTAL
15
Hydro Gate Installation, Operations and Maintenance

Hydro Gate
Cleaning and Final Adjustment of Gate
1. Move the slide to the fully opened position.
Cast Iron Slide Gates
2. Clean all dirt, grit, paint or other foreign material off of the gate seating faces and wedging surfaces
on both the slide and frame.
3. Grease the seating faces and wedge surfaces with water-resistant grease such as the following:
• Conoco's All Purpose Superlube
• Texaco's Multi-Fak Heavy Duty No. 2
• Shell Oil Company's Alvania No. 1
• Lubriplate No. 630 AAA
• BP Energrease LS 2
Safety Note
Lubriplate Super FML2 has a vegetable base and is recommended for use on gates in potable water
treatment plants.
4. Close the gate completely and check for proper wedge adjustment per this Manual.
Wedge Adjustment
All wedging devices were adjusted for proper metal -to -metal contact before shipping. Vibration during
shipment or normal handling during installation may cause some loosening or changing of these settings.
After installation with the slide in the fully closed position, use a .004 -inch feeler gauge to check excess
clearance between the seating faces. For best results, make this check from the backside of the slide.
If a .004 -inch feeler gauge is admitted between the seating faces along the top near the stem, excess
compression on the stem may be causing a slight deflection of the slide. To relieve and correct this
problem, turn the crank or handwheel in the direction to open the gate until it turns freely. Re -check the
clearance with a feeler gauge. If the wedge settings have been changed during installation or if it is
necessary to readjust all wedging devices, a suggested order of adjustment is shown in Figure 10. The
number of wedges may vary, but the pattern of adjustment should be similar.
16
Hydro Gate Installation, Operations and Maintenance

Hydro Gats
------------------------------------------------------------------------------ Cast Iron Slide Gates
Top and Bottom Wedge Adjustment
1. Loosen adjusting screw "H" and then loosen cap screws "F" a fraction of a turn until tapping lightly
can move the wedge block (Figures 11 and 12).
Installation Note
Do not loosen adjusting screws too much as leakage or damage to the wedges can occur when the
wedge is readjusted and tightened.
2. Tighten adjusting screw "H" (The torque on the adjusting screw is variable, but should not normally
exceed values in the torque table for fasteners).
3. Tighten the cap screw 7".
4. Tighten the lock nut "G".
5. Open the gate approximately 1 inch and retighten capscrew F.
Figure 10 - Gate Wedge Adjustment Sequence
9
8
5
4
1
21 20 17 18 19 22
10
7
6
3
2
17
Hydro Gate Installation, Operations and Maintenance

Hydro Gate
Figure 11- Top Wedge Adjustment
Lock Nut
..G..
Cap Screw
.. H..
Figure 12 - Bottom Wedge Adjustment
Lock Nut
..G..
Cap Screw
..H..
Wedge
Hook
Cap Screw
.T"
Wedge
Frame
Slide
18
Hydro Gate
Cast Iron Slide Gates
Cap Screw
..F..
Wedge
Hook
Wedge
Gate Fully
Closed
Gate Fully
Closed
Frame
Installation, Operations and Maintenance

X01 Hydro Gate
Side Wedge Adjustment
Cast Iron Slide Gates
1. Loosen the nut on the stud through the wedge until tapping lightly can move wedge (Figure 13).
2. Be certain that the bolts holding the wedge block to the frame are tight. See the torque table below.
3. With a punch or discarded bolt, drive the wedge down until firm contact is made with the overhang
portion of the wedge block and the seating faces are pushed together. Do not over -drive any wedge,
because it may cause premature engagement when closing. Check all wedge faces for uniform and
simultaneous contact during closing.
4. Tighten the nut on the stud through the wedge. (See torque table below for proper tightening.)
Torque Table for Tightening Nuts or Hex Bolts Used for Assembly
Capscrew Diameter
(Inches)
3/8
1/2
Torque Specifications
(Pound Feet)
20
45
75
5/8
3/4
125
7/8
200
1
300
1 1/8
450
1 1/4
500
1 1/2
600
Use "Anti -Seize" Lubricant on All Threads.
19
Hydro Gate Installation, Operations and Maintenance

Hydro Gate
Figure 13 - Side Wedge Adjustment
Fi
Stu(
Wedge
Block
Flush Bottom Closure Adjustment
Cast Iron Slide Gates
Seating
Surface
Wedge
Slide
All flush bottom devices were factory adjusted for proper contact before shipment. Shipment and normal
handling may have caused loosening or changing of the settings. Use the following procedures to
readjust.
On those gates having flush bottom closure, move the gate slide to its fully closed position by
applying force on the handwheel or the crank of the lift. Uniform contact between the bottom lip of the
gate slide and the top surface of the rubber seal must be made for the full width of the gate opening.
Check for proper contact with a .004 -inch thickness feeler gauge.
2. If full closure is not being made, open the gate a fraction of an inch to relieve pressure on all of the
wedges. Loosen all of the nuts on the studs through the side and wedges and top wedges (if used),
as explained this manual.
3. Re -close the gate until uniform contact is made between the bottom of the gate slide and the rubber
seal. A slight deformation of the seal is required for the full width of the gate.
4. Adjust and retighten all wedges, as explained in this manual.
5. Grout or fill the bottom recess around the flush bottom closure as required.
20
Hydro Gate Installation, Operations and Maintenance

Hydro Gats
------------------------------------------------------------------------------ Cast Iron Slide Gates
Manual Lifts, Parts, and Assemblies
Typical assemblies of manual lifts are included for reference. These lifts may be either bench -mounted or
pedestal -mounted. All Hydro Gate's lifts have bowls or housings that can be removed from the pedestal,
leaving the lift nut in place supporting the gate weight. If inspection or service of the gears and bearings
is necessary, remove the bowl/housing cap screws and lift the bowl off.
Bench -mounted lifts must be removed from the stem to disassemble the bowl, because the heads of the
bowl cap screws are under the base or bearing flange.
Hydro Gate's lifts may be arranged in tandem. These lifts are connected with an interconnecting shaft,
sometimes called a tandem shaft. See the gate installation drawing for more information.
The assembly of tandem lifts requires the following:
1. Reference is made to Hydro Gate's installation drawing.
2. The proper hand of stem is in the proper place on the gate.
3. The stems and lifts are synchronized so that the gate lifts evenly.
Synchronization is accomplished with the interconnecting shaft coupling, (i.e., make up the coupling when
the gate and stems are even and level.)
21
Hydro Gate Installation, Operations and Maintenance

J Hydro Gate
OPERATION
General Operation Information
Cast Iron Slide Gates
Cast Iron Slide 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 accurate control of liquid flow.
The simplicity of a Cast Iron Slide Gates makes it a popular choice when designing flow controls. From
the basic hand -cranked manual model to the microprocessor -controlled, fully integrated electric Cast Iron
Slide Gates, actuation consists of the basic open or closed operation. An open gate allows flow and a
closed one does not.
Depending on size, most Cast Iron 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.
Cast Iron Slide Gate Operation Procedures
The following sections cover the general operating procedures associated with two manual -operation
systems (handwheel and handcrank) and an electrical -operation system. Read and follow the operating
procedures for the applicable system. If you have any questions concerning safe operation of this Hydro
Gate Cast Iron Slide Gates, contact Hydro Gate immediately.
22
Hydro Gate Installation, Operations and Maintenance

Hydro Gats
------------------------------------------------------------------------------ Cast Iron Slide Gates
HB Series Actuator (Manual Handwheel or Tee Wrench)
Opening — To open this Cast Iron Slide Gate observe the direction of rotation noted on the handwheel. Turn
in the direction of opening. If the gate has been closed for an extended period the gate may be difficult to
"unseat." If, after several turns of the wheel, the rotation becomes increasingly difficult stop rotation when a
moderate pressure is achieved. Allow the pressure in the stem to unseat the gate (a "POP" sound typically
signals the gate has begun to travel. Continue to turn the hand wheel 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.
Operation Note
Do not over -open the gate. Serious damage to the gate stem and sealing surfaces can result.
Closing — To close this Cast Iron Slide Gate turn the handwheel in the direction opposite of the Open indicator
until the stopnut on the stem has moderately seated on the top of the lift. 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 Hydro Gate before any adjustments are made.
Operation Note
Do not attempt to adjust the position of the stopnut to achieve additional closing stem travel. Serious damage
to the gate stem and sealing surfaces can result.
CPS Series Actuator (Manual Handcrank)
Opening — To open this Cast Iron Slide 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, after several turns of the handcrank, the rotation becomes increasingly difficult stop rotation when
a moderate pressure is achieved. Allow the pressure in the stem to unseat the gate (a "POP" sound typically
signals the gate has begun to travel. Continue to turn the handcrank until the desired gate position has been
achieved.
Operation Note
Do not over -open the gate. Serious damage to the gate stem and sealing surfaces can result.
Closing — To close this Cast Iron Slide Gate turn the crank in the direction opposite of the Open indicator until
the stopnut on the stem has moderately seated on the top of the lift. 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 Hydro Gate before any
adjustments are made.
Operation Note
Do not attempt to adjust the position of the stopnut to achieve additional closing stem travel. Serious damage
to the gate stem and sealing surfaces can result.
23
Hydro Gate Installation, Operations and Maintenance

Hydro Gate
MAINTENANCE
Field Cleaning and Painting
Cast Iron Slide Gates
Hydro Gate's standard paint system on Cast Iron Slide Gates is commercial grade blast and Hi -build
epoxy paint. It does not require top coating. Should blast cleaning be needed to condition the gate for
top coating, the gate should be fully closed and any exposed metallic seating faces, wedges, and wedge
blocks protected from blast and paint. Before painting, blow all grit off gate, particularly in and around the
seating faces. Do not remove any wedges or disassemble the gate except as described in the next
paragraph.
Hydro Gate does not usually recommend removing the slide from the frame to apply finish/top coats
because of the risk of damage to the seating faces during handling. If sufficient reasons exist for removal
of the slide, (e.g., badly deteriorated paint on an old gate or a complete change of paint system that is
incompatible with the existing paint) then completely disassemble and thoroughly blast clean all surfaces
to obtain a quality recoated product.
When disassembling the gate or gates, keep parts segregated and match -marked so that parts are not
mixed gate -to -gate because interchangeability between gate parts is not always certain. Protect all
seating surfaces on the slide and frame with duct or masking tape. Use special care in handling the slide
and frame to avoid damage to the seating faces.
Blast clean and paint the frame and slide as required by the specifications or the paint manufacturer's
recommendations. Do not paint the contact faces of the wedges or metal seat. Remove masking tape or
other material used to protect machined faces. Clean all faces thoroughly and relubricate. Reinsert
slides in the proper frame.
With the gate in the fully closed position, recheck maximum clearance between the seating faces with
.004 -inch thickness feeler gauge. Readjust wedges, if required, per the instructions in this Manual.
24
Hydro Gate Installation, Operations and Maintenance

.d�
Hydro Gats
------------------------------------------------------------------------------ Cast Iron Slide Gates
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 the stem threads by brushing or smearing grease onto/into the threads as the gate is closing (the
stem is lowering 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. Of course, replenish grease on the underside stem.
The recommended stem thread lubricant is a mixture of "La Co Slic-Tite Paste" and Fiske Bros. "Lubriplate No.
630 AAA" in the ratio of 24 ounces of paste per gallon of grease. "Slic-Tite Paste" is a pipe dope with Teflon
fibers and is available from most plumbing supply stores or from:
La Co Industries, Inc.
1201 Pratt Blvd.
Elk Grove Village, IL 60007
Phone: [phone]
Fax: [phone]
Web site: www.laco.com
An equal alternate for La Co's "Slic-Tite" is "Dayton Pipe Thread Sealant Paste with Teflon", Stock Nos. 4X222
or 5X998, which is available at W. W. Grainger Inc. stores in major cities nationwide.
Equivalent lubricants to Fiske Brothers' "Lubriplate 630AAK include:
Conoco's "All Purpose Superlube"
Texaco's "Multi Falk Heavy Duty No. 2"
Shell Oil Company's "Alvania No. 1"
Mobil's "Mobilux EP2"
BP Energrease LS 2
Fiske Brothers' "Lubriplate No. 630 AA"
A recommended lubricant for potable water service is a vegetable-based lubricant, "Lubriplate Super FML -2".
Handwhell type lifts do not have Zerk Fitting. The stem cover must be removed to facilitate stem
lubrication.
Manual crank lifts have sealed thrust bearing and do not require lubrication.
Exercise of infrequently operated lifts and gates is recommended. An annual exercise will ensure the
gate is operable when needed and the lubrication condition will be maintained.
Removal of the stem nuts for thread inspection of frequently modulated gates is recommended. This avoids
"surprise" when the nut threads have worn so thin they strip out and drop the gate. Replacement or spare nuts
can be ordered from Hydro Gate. Spare parts are usually not needed or recommended, since they are readily
available on short notice from Hydro Gate. In those cases where equipment operation or downtime is critical
and the gate is operated extremely often, a spare lift nut may be wise to have on hand.
26
Hydro Gate Installation, Operations and Maintenance

Hydro Gate
Maintenance and Lubrication
Cast Iron Slide Gates
Occasional adjustment, lubrication, and painting of Hydro Gate Cast Iron Slide Gate components will be
required. The frequency will depend upon how often the gate is used, location, and operating conditions.
Periodic inspection, adjusting, cleaning, and repainting are recommended as conditions at the site permit.
When excess leakage through the gate seating surfaces occurs or when the gate has been in the closed or
opened position for long periods of time without movement, the seating faces and wedging surfaces should be
cleaned and greased and the wedges should be readjusted per the instructions in this manual.
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.
Maintenance Note
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 as follows:
Initial inspection - after 25 cycles of gate operation.
Subsequent inspection - after 50 cycles of gate operation.
Operational inspection - after each 100 cycles of gate operation or six months, whichever occurs first.
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.
Check the amount 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 away 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.
25
Hydro Gate Installation, Operations and Maintenance

Hydro Gate Cast Iron Slide Gates
Maintenance Schedule and Lubrication Summary
Activity —1I Frequency II Lubricant
General Cleaning andII As often as conditions require or N/A
Inspection permit, or every 6 months.
Stem Thread and Lift Initial inspection after 25 cycles. N/A
Nut Wear Inspection Subsequent inspection after 50
cycles. Operational inspection
after each 100 cycles, or every 6 Ij
months. I
Stem Thread
Lubrication and
Cleaning Inspection
After 100 cycles or 6 months.
Clean grease if dried or contains
foreign material.
Mixture of 24 fluid ounces La Co Slic-Tite
Paste and 1 gallon of Fiske Bros. Lubriplate
No. 630 AAA or AA. (An equal alternate is
Dayton Pipe Thread Sealant Paste with
Teflon, Stock Nos. 4X222 or No. 5X998)
Clean and Grease Annually or whenever the gate is " *Fiske Bros. Lubriplate No. 630 AAA or AA.
Seating Faces and I dewatered. Exercise gate, at
Wedge Surfaces I least partially, every 6 months if
dewatering, inspection, cleaning,
and lubrication are not possible.
___1L
*Equivalent lubricants to Fiske Bros.
Lubriplate No. 630 AAA or AA include the
following:
Conoco's All Purpose Superlube
Texaco's Multi Fak Heavy Duty No. 2
Shell Oil Company's Alvania No. 1
Mobil's Mobilux EP2
Exxon's Ronex MP
Notes
• Inspect crank lift for the collection of moisture beneath the stem cover housing. Unthread the stem cover
housing and examine the space surrounding the stem. A convenient method of removing the moisture is by
utilizing a Squeeze Bulb, Siphon or Baster.
• For potable water treatment plants use a vegetable-based lubricant such as Lubriplate Super FML -2.
• La Cc Slic-Tite Paste is available at plumbing supply stores or from La -Co Industries, 1201 Pratt Blvd., Elk
Grove Village, IL 60007 [phone].
27
Hydro Gate Installation, Operations and Maintenance

NttC dr Gate
.
------------------------------------------------------------------------------
Cast Iron Slide Gates
Lubrication Equivalents
Hydro Gate considers any of the following greases/lubricants to be acceptable
A. Fiske Brothers "Lubriplate" No. 630 AAA or AA
B. Sta-Lube "Sta-Lube" No. 3121
C. Conoco "All Purpose Superlube"
D. Texaco "Multi Fak Heavy Duty" No. 2
E. Shell Oil Company "Alvania" No. 1
F. Mobil "Mobilux EP2"
G. Exxon "Ronex MP"
Hydro Gate recommends the following pipe thread sealants with Teflon:
A. La -Co Slic-Tite Paste
B. Dayton Pipe Thread Sealant with Teflon\
C. McMaster -Carr Pipe Thread Sealant with Teflon
D. Any other commercially available pipe thread sealants containing Teflon.
For water treatment plants, Hydro Gate recommends using a vegetable-based lubricant such as
Lubriplate Super FML -2.
Interchangeable
28
Hydro Gate Installation, Operations and Maintenance

Hydro Gate
Leakage
Cast Iron Slide Gates
The most frequent cause of excess leakage through a newly installed Hydro Gate Cast Iron Slide Gate is
improper installation and/or failure to make final adjustments before the gate is put into operation. When
you encounter this problem, first verify that Hydro Gate's installation instructions have been carefully
followed and that final adjustment and greasing have been accomplished. If not, then complete the
applicable step-by-step procedures of adjusting and greasing as outlined in the appropriate provided
instructions.
Another important check is to ensure the Cast Iron Slide Gates were not disassembled for installation.
The cover of this Installation, Operation, and Maintenance Manual states "DO NOT DISASSEMBLE
GATE FOR INSTALLATION". This is repeated in the text of this manual at several critical locations.
Occasionally, we still find that gates are disassembled for easier handling, painting, etc.
Installation Note
When the Cast Iron Slide Gate is disassembled for installation, all of the fine adjustments that were made
by Hydro Gate are lost. It is then necessary for you to clean all of the contact faces, reinstall the slide,
and adjust all wedging devices in strict accordance with our instructions.
As pointed out above and in our installation instructions, the amount of leakage through the Cast Iron
Slide Gate is highly dependent upon the quality of installation. On the gate seat, or frame is somewhat
flexible and is easily pulled out of line if incorrectly installed, resulting in leakage. The amount of leakage
depends upon the deflection of the castings by improper tightening of the nuts on the anchors.
To minimize leakage through Cast Iron Slide Gates and meet or exceed the AWWA C560 Cast Iron Slide
Gate Standards, installation must be precise. Our instructions not only call for careful installation of
gates, but also emphasize the importance of final cleaning and lubrication of seating faces and wedge
contact surfaces before operating the gate. We also recommend a water-resistant grease be applied to
all surfaces, which allows proper seating of the gate in the last turn or two of the hand crank.
Example
When the slide is moved downward by as little as 1/64 of an inch, the wedges cause it to move toward
the seating surface by .002 inch. This almost negligible horizontal movement can cause a considerable
difference in the amount of leakage.
The American Water Works Association's (AWWA's) leakage rate for Cast Iron Slide Gates is 0.1 gallon
per minute per foot of seating perimeter for seating heads and 0.2 gallons per minute per foot of
perimeter for unseating heads up to unseating head of 20 ft. Unseating heads above 20 ft. require the
allowable leakage to be calculated. Maximum allowable leakage for unseating heads above 20 ft.
(gallons per minute per foot of seating perimeter) = .10 + 0.005 (unseating head in feet).
29
Hydro Gate Installation, Operations and Maintenance

Hydro Gats
------------------------------------------------------------------------------ Cast Iron Slide Gates
Troubleshooting Tips for Hydro Gate Cast Iron Slide Gates
Excessive Leakage under Slide on Flush Bottom Closure
Excessive leakage occurring with a uniform sheet of water flowing underneath the gate slide indicates
that some or all of the wedges are too tight and the slide is being stopped short of its fully closed position.
Locate the mistightened wedges with a .004 inch feeler gauges. Tight wedges will not permit insertion of
the gauge. If only one or two wedges are the problem, readjust them. It may be necessary to completely
loosen and readjust the entire gate per the instructions in this manual.
Excessive Leakage along the Sides and/or Top of the Slide with flush Bottom Closure
With the gate fully closed, excess leakage can occur at the sides and along the top. Check for proper
contact between the bottom of the slide and the face of the flush bottom seal. It is likely that one or more
of the side wedges, or the top wedges, at the location where leakage is occurring, is too loose. Adjust the
side and top wedges as described under the Wedge Adjustment section of this manual.
Excessive Leakage at One Particular Location
Excess leakage occurring at one particular location indicates one wedge is improperly adjusted. Check
between the tapered face of wedge and the wedge block with .004 -inch thickness gauge. If the gauge
passes between these surfaces, readjust that wedge. Even if the gauge cannot be passed between the
tapered wedge faces, loosen the nut on the stud through the wedge and adjust the wedge tighter.
If you are unable to correct the leakage by readjusting the wedge, it may be caused by foreign material
between the gate seating faces. Open the gate an inch or two. If a large piece of foreign material is
found, flush it out. If the leakage persists, foreign material such as paint or grit may be on the seating
faces. To correct this problem, dewater the gate completely, clean all seating faces and wedge surfaces,
and grease the faces. Follow the procedures under the Clean and Adjust Gate section of this manual.
Excessive Leakage along Top; Stem Block Pocket Located at or Near Top of Slide
Leakage is occurring at the center top of the gate only. With this slide configuration, it is possible to push
down on the stem so hard that the stem block is pulling the gate slide from its seating faces at the top.
Turn the handwheel, gear crank, or power actuated lift to relieve the compression on the stem and the
excess force on the top of the slide. If the slide was being deflected, the excess leakage will diminish or
stop when the compression in the stem is relieved.
Maintenance Note
Do not raise the slide from its wedges. Actuate the lift only enough to allow the stem to relax.
To prevent the slide from deflecting at the stem block, readjust the stop nut on manually operated lifts, or
the torque and limit switches on electrically actuated lifts.
30
Hydro Gate Installation, Operations and Maintenance

Hydro Gate
Cast Iron Slide Gates
Excessive Localized Leakage; Gate Installed on Concrete, Wedges Tight
This indicates the frame was warped from true flat plane by overtightening of anchor bolts. Loosen the
bolts in the area of the leak. The frame will usually spring back. Check the seating face with a .004 -inch
gauge. Check the wedge adjustment. Shim as required between the gate frame and wall. Retighten the
bolts. Caulk or regrout to seal off the crack or gap between the frame and wall.
If the warp is severe, it may save time to completely remove the gate and reinstall the gate on new grout,
or a bead of epoxy or sealant such as Sikaflex 1-A. Be careful so that the gate is installed flat the second
time. Review the proper installation and adjustment instructions in this manual.
Dirty Seating Faces
Excess leakage can be caused by foreign material on the seating faces of the gate frame or slide. Check
for drops of paint, cement runs onto seating faces, or other construction grime. To correct, scrape off the
foreign material from the perimeter of the seating faces on both the slide and frame and reseat the gate.
Cast Iron Slide Gates Installed on Wall Thimble - Excessive Leakage
Gates installed on thimbles may have improper sealing material or compression on the gasket between
the gate back and thimble face. Foreign material on the thimble face will hold the gate from properly
contacting the thimble. Loosening nuts on all studs, pulling gate from the thimble, or gate removal are the
solutions. Clean and reseal as described in Installation of Wall Thimble section of this manual.
Leakage between the machined faces will also occur if mastic was not applied continuously around the
perimeter of the front face of the thimble, or if it was applied sparsely in any one location. One or more
spots without mastic, or too little mastic, will cause leakage between the back of the gate and the front
face of the thimble. To correct, loosen all fasteners, move the gate out on the studs, reapply mastic to
the front face of the thimble and uniformly tighten the nuts.
Occasionally, improper thimble installation may cause leakage. The thimble can be warped out of true
flat plane through incorrect installation or improper blocking of the opening before concrete is poured.
Check thimble warp with straightedges or thin wires. The wires should be tightly stretched diagonally
across the opening to form an "X". If these wires touch at the center, reverse them to place the top
diagonal wire underneath the other wire to make sure that the warping of the thimble isn't actually causing
the wires to touch at the center. Thimble warp may also be checked with a pair of plumb bobs. Suspend
each past the top horizontal seating face near each side of the opening. The bobs should be equidistant
from the lower horizontal seating face.
Straightness of individual thimble sides can be checked with one wire, or a straightedge to ensure each
face is straight. Except in a few cases when thimble warping is severe, shimming to support the back of
the frame can properly align the gate frame. Tighten the nuts on the studs uniformly. Epoxy sealant can
then seal the space between the front face of the warped thimble and the back of the gate frame. Severe
thimble warping may require gate removal to remove old mastic. Shim and block between the thimble
and frame to maintain a true flat plane and then fill the gap with fresh mastic. Adhesive grout contractors
can inject epoxy between thimble and frame, which hardens to a variable thickness load bearing shim or
gasket and can be injected into tiny spaces to ensure water tightness.
31
Hydro Gate Installation, Operations and Maintenance

Hydro Gate
Stem Bends when Gate Is Closed
Hand -Operated Lifts
Cast Iron Slide Gates
1. Ensure the stem guide collars are properly located to hold the stem in alignment. The bolts on the
collars must be tightened so the collar is not slipping on the guide bracket.
2. Ensure the stem guides are all located properly. If the spacing exceeds that shown on Hydro Gate's
installation drawings, the stems may be deflecting before the gates are closed tight.
3. If stem guides are correctly located and collars are tight, then the load applied to the stem by the lift is
in excess of that needed to close the gate, or the load recommended for a particular stem size. Reset
the stop nut to prevent an excess load from being applied to the stem after the gate is closed.
Excess Force Is Required on Handwheel or Crank
1. Ensure the stem is lubricated as recommended.
2. If application of lubricant does not solve the problem, check for foreign material in the nut threads
either by disassembly or working back and forth with application of penetrating oil and grease.
3. If properly greased and lift nut is not binding, ensure the stem, stem guides, and lift are aligned. A
carpenter's level can verify it is in plane in both directions. Check for binding through individual stem
guides. Ensure pedestal is vertical in both directions and the stem threads straight through the lift nut.
4. In locations where the stem is not installed vertically, alignment can be checked by using a thin wire
stretched between the slide top and the lift bottom. Realign by adjusting stem guides and/or
shimming less than one side of the lift.
5. Check condition of the seating faces. A rough or galled seat can cause additional friction load.
Depending on severity, the faces may be filed or sanded smooth. Some sealability may be sacrificed.
32
Hydro Gate Installation, Operations and Maintenance

Hydro Gate
Cast Iron Slide Gates
Long -Term Storage Instructions for Cast Iron Slide Gates, Lifts, Stems, and Accessories
Gate assemblies must be stored horizontally and flat, with the backside (flange side) down. The
storage area must be flat, graded, comprised of compacted soil, concrete, or asphalt. Storage on
uneven surfaces can cause permanent distortion of the gate, creating installation problems.
2. Place timber, minimum 4 -inch x 4 -inch, to provide substantially complete perimeter support under the
gate frame assembly. Longitudinal timbers, spaced a maximum of 4 feet, may also be used.
3. Stacking of gates is permissible. The stacked height should not exceed 3/4 of the bottom gate's
width or height. Stack gates of different sizes in a pyramid fashion. Do not stack large gates on top
of smaller gates.
4. Stacked gates should be separated with timber. The separating timbers should form a flat and level
base for the gate above.
5. Wall thimbles may be stored similar to above with machined flange face up or down. Substantial
level blocking is essential. Uneven support of gate assemblies and thimbles causes the gate or
thimble to warp and voids the manufacturer's warranty.
6. Store the lift assemblies either upright with plastic plugs/caps in place to keep dirt out of the nut
threads or leave in original shipping cartons. Do not store the lifts directly on the ground.
7. Stems and stem covers should be stored horizontally on timbers spaced 4 to 8 feet apart. Protective
sleeves should be left on all stem threads and stem covers.
8. Miscellaneous accessories and hardware should be stored off the ground.
9. Bronze stem blocks, wedges, lift nuts, and stainless steel accessories are targets for theft and resale
as scrap. Report all shortages at once and note same on shipping papers. Hydro Gate cannot be
held responsible for theft and loss of equipment stored on the job site.
10. Inside dry storage is the best for all equipment. Covering equipment stored outside with tarpaulins is
recommended to minimize degradation of paint from rain and sunlight, until finish paint is applied.
Uncovered outdoor storage may result in staining of painted surfaces from rain and sunlight.
33
Hydro Gate Installation, Operations and Maintenance

Hydro Gate
WATER CONTROL GATE GUARANTEE
Cast Iron Slide Gates
For a period of one year from the date indicated, Hydro Gate hereby guarantees that its water control
gates will be free from defects in material and in workmanship and agrees to repair or, at its discretion,
to replace any part or parts found defective within such one year, provided the Purchaser gives
immediate notice of such defect, and such defect, in the opinion of Hydro Gate clearly demonstrates
the existence of defective materials or workmanship.
This guarantee is applicable only if the product is properly stored and protected as prescribed by us,
between the interval of its receipt by the Buyer and actual installation and if the product is properly
installed and lubricated in accordance with our instructions.
The liability of Hydro Gate shall not in any case exceed the cost of repairing or replacing the defective
parts. The guarantee and the remedies provided for defective parts set forth above are in lieu of and
shall supersede any and all guarantees or warranties, express or implied, or remedies provided by law
or otherwise (including those set forth in purchase order forms or other sales documents). In no event
shall Hydro Gate be liable for loss of income, any other expenses, consequential damages or incidental
damages. At the end of said one year, all liability of Hydro Gate shall cease and terminate.
Hydro Gate guarantees equipment of other manufacturers only insofar as such equipment is
guaranteed to it. Information with respect to such guarantees is available on request.
34
Hydro Gate Installation, Operations and Maintenance

Hydro Gate
I NO. I PARTS LIST I
FLANGE FRAME
DOVETAIL METAL SEATING FACES
SIDE WEDGE BLOCK
SIDE WEDGE BLOCK FASTENERS
TOP WEDGE
TOP WEDGE FASTENERS
BOTTOM WEDGE
BOTTOM WEDGE FASTENERS
STANDARD BOTTOM SLIDE
SIDE wEOGE
SIDE WEDGE FASTENER SET
TOP WEDGE HOOK
TOP & DDTTOM WEDGE HOOK FASTENER SET
BOTTOM WEDGE HOOK
TOP & BOTTOM WEDGE HOOK ADJUSTING SCREW SET
Cast Iron Slide Gates
m
11
;LIDS ASSEMDLY
13
SERIES 501 HEAVY DUTY SLUICE GATE
STANDARD BOTTOM
NOT SELF CONTAINED, FULL WEDGING
Hydro
Gate
35
Hydro Gate Installation, Operations and Maintenance

Hydro Gate
0
0
z
0
FRAME ASSEMBLY
12
0
��_�MONSOON
(ON BACK
FACE)
NO. PARTS LIST
1. FLANGL FRAME
2. DOVETAIL METAL SEATING FACE
3. SIDE WEDGE BLOCK
4- SIDE WEDGE BLOCK FASTENERS
5. TOP WEDGE
6. TOP WEDGE FASTENERS
7. FLUSH BOTTOM SLIDE
8. SIDE WEDGE
9. SIDE WEDGE FASTENER SET
10. TOP WLDGE HDOK
11. TOP WEDGE HOOK FASTENER SLT
12. FLUSH BOTTOM SEAL RETAINER FASTENERS
13- SEAL RETAINER FLAT
14. FLUSH BOTTOM RESILIENT SEAL
15. FLUSH BOTTOM ANGLE
I6- FLUSH BOTTOM ANGLE FASTENERS
17. WEDGE H009 ADJUSTING SCREW SET
Cast Iron Slide Gates
SLIDE ASSEMBLY
SERIES 501 HEAVY DUTY SLUICE GATE
FLUSH BOTTOM
NOT SELF CONTAINED, FULL WEDGING
Hydro
Gate
36
Hydro Gate Installation, Operations and Maintenance

Hydro Gate
GREASE
RESERVOIR
7
{c
Cast Iron Slide Gates
NO.
QTY.
—...—PARTS ..LIST ....._.
1
1
AWWA 2" SO. CRANK ADAPTOR
2
1
INPUT SHAFT/PINION GEAR
3
1
INPUT SHAFT 0 RING SEAL
4
2
INPUT SHAFT BEARINGS
5
1
INPUT HOUSING
6
1
IDENTIFICATION TAG
7
1
STEM COVER ADAPTOR W/ ZERK
B
1
STEM COVER
9
1
STEM COVER MOUNTING U BOLT
10
1
PRIMARY GEAR HOUSING
11
1
BEVEL GEAR 0 RING SEAL
12
1
BEVEL GEAR
13
1
BASE PLATE
14
1
SPIGOT RING 0 RING SEAL
15
1
SPIGOT RING
16
1
LIFT NUT
17
1
FABRICATED PEDESTAL
18
4
THRUST WASHERS
19
2
THRUST BEARINGS
20
1
DRIVE NUT 0 RING SEAL
+
LUBRICATION PRESENT
HYDRO GATE CPS SERIES LIFTS
37
Hydro Gate Installation, Operations and Maintenance

J Hydro Gate
SPARE PARTS
Cast Iron Slide Gates
Warnings
- Check size of parts before attempting to store them
- Spare parts should be stored in clean, dry and protected warehouse until ready for installation.
HOW TO ORDER REPLACEMENT OR SPARE PARTS
Parts may be ordered from your local Hydro Gate Representative or direct from Hydro Gate.
Please have the following information:
1. Hydro Gate sales information found on the blue anodized tag located on the gate or pedestal.
2. The item and/or tag number must be relayed to Hydro Gate
3. Description of replacement Part(s)
Spare Parts List
1 Stop Nut
2
Stop Collar
3
Lift Nuts
4
Stem Cover
5
Thrust Bearing for Gate lift
38
Hydro Gate Installation, Operations and Maintenance