PLEASE NOTE: The equipment you have purchased is a quality product which

will give you many years of trouble free operation if minimal maintenance is
routinely performed. A few notes at this point will familiarize you with the general
aspects of the equipment and of the manual included herewith. The model number
and capacities are stamped on the nameplate attached to your equipment.
Adherence to those capacities will prevent damage. This manual includes Safety
Precautions, Operating Instructions, General Information, Specific Diagrams and
Instruction on Troubleshooting in the Electrical and Mechanical Sections and
General Periodic Maintenance. This manual shall act as guide to understand the
operation of the machine. General useful additions will be added to inform and
simplify any service that may be required to enhance the performance of the
machine. Each machine delivered will have a manual which should be kept at the
place of installation of the machine. Additional copies of the manual can be
requested to us. In final note, we are an organization with an open mind. Your
constructive thoughts or criticism are always considered. Your suggestions as end
users of the equipment enable us to constantly improve the performance of our
products. We would appreciate hearing your ideas. TECH SUPPORT:
If you have any concerns with our equipment or need further information, please
contact us. Our Technical Support Department is open Monday through Saturday,
from 10am to 6pm IST:
 --: TABLE OF CONTENTS:--

SR. NO. DESCRIPTION PAGE NO.

1.0 SILT FULUSHING 05
TUNNEL SERVICE &
EMERGENCY GATE
1.1 TECHNICAL DATA 05
1.2 DESCRIPTION OF 06
GATE
1.3 INSPECTION OF SFT 06
GATE
1.4 MAINTENANCE 07
SCHEDULE OF SFT
GATE
1.4.1 MONTHLY 08
MAINTENANCE
1.4.2 QUATERLY 08
MAINTENANCE
1.4.3 ANNUAL 09
MAINTENANCE
1.5 GENERAL 10
MAINTENANCE OF
SFT GATE
1.5.1 EVERY THREE YEARS 10
1.5.2 EVERY SIX YEARS 10
1.6 LIST OF DRAWINGS 11
FOR SFT GATE
2.0 HYDRAULIC HOISTS 12
AND POWER PACKS
FOR SFT GATE
2.1 TECHNICAL DATA OF 12
HYDRAULIC HOISTS
2.2 TECHNICAL DATA OF 12
POWER PACK
2.3 DESCRIPTION OF 13
HYDRAULIC
CYLINDERS AND
POWER PACK
2.4 OPERATION OF SILT 13
FLUSHING TUNNEL
 The equipment’s described should be maintained & operated by trained,
skilled & experienced personnel only. To ensure safe & trouble free operation of
the HM Equipments please follow all the instructions and operating procedures
listed in this manual. Failure to follow these instructions can lead to fatal accidents
OR serious injury to humans as well as damages to the HM Equipments and its
surroundings. It can also lead to troublesome and reduced operating life of the
Equipment. If you experience any difficulty in Operation of the HM Equipments
and find any faults in the equipment, please bring it to the notice of our technical
support department at GMW Pvt. Ltd, Vadodara. We recommend use of GMWPL
genuine spares only to ensure trouble free and long life of the HM Equipments.
Use of any other spares may lead to major damages to the Machine. GMW PVT
LTD will not be responsible for any consequences, mishaps, accidents, injuries,
brakeage, and damages occurring due to non compliance / non conformance of the
above instructions. Non-Conformance of the above instructions shall lead to
cancellation and withdrawal of all guarantee and warranty coverage of this HM
Equipments. WARNING: Please study the operator instructions and the safety
interlocks carefully and understand them well before operating the machine.
1.0 SILT FLUSHING TUNNEL SERVICE AND MAINTENANCE GATE:
1.1 TECHNICAL DATA:

Sr. No. Description Data

1) Clear width of : 1750 mm
gate
2) Clear height of : 1800 mm
gate
3) Height of gate : 2040 mm
panel
4) Width of gate : 1300 mm
panel
5) C/C of side seals :
1035 mm for
Rubber seals
1255 mm for
Metallic seals

6) Distance between :
sill level to Cl. of 1880 mm for
top seal Rubber seals
1990 mm for
Metallic seals

7) Design head : 50 m
8) Sill level of gate : EL 1730.00 m
9) Operating floor : EL 1750.20 m
level
10) Maximum water : EL 1852.00 m
level
11) Type of sealing : Double stem side
& Top seals, Flat
type bottom seal,
Additionally
metallic sealing
are provided to
gate
12) Hoisting : Double acting
arrangement hydraulic hoist
13) Capacity of hoist : 65 MT
1.2 DESCRIPTION OF GATE : Two flushing systems (one for each desilting
chamber) are provided for flushing silted water in the desilting chambers. The
trench at bottom of desilting chamber shall convert into the closed rectangular duct
at the end of each desilting chamber. These ducts are housed in silt flushing tunnel.
Each duct shall be operated by a Service gate. This allows flushing of the different
sections independently. Each gate is bonnet type gate having upstream skin plate,
downstream rubber and metallic seals and bonnet top with double acting hydraulic
hoist for silt flushing. An additional Maintenance gate is also provided at upstream
of service gate for maintenance of the service gate. Normally service gate will be
in closed position and used when desilting requires. Maintenance gate will be
closed when service gates are under maintenance. Control system for operation of
gate includes distribution boxes for the connection of the gates operation
mechanisms and position sensors and alarm/status indicators to the distributed
control system of the plant allowing the gates to be remote controlled and operated
by the Main Control Room (MCR) in the powerhouse. SFT gates are vertical slide
type bonnet gates operated by means of hydraulic cylinder. The top of each gate is
provided with an enclosed bonnet which has adequate space to store gate leaf when
gate is in open position. On top of bonnet a bonnet cover with housing arrangement
is provided to mount the hydraulic cylinder. It must be raised and lowered slowly
to avoid surge/vacuum in the tunnel. This gate is provided for evacuation of silt
from desilting chamber. The gate is a rigid panel with skin plate mounted on a
structural frame. It is so designed that it can withstand the water pressure arising
due to the difference in water level across the gate. The gate panels are equipped
with rubber and metallic sealing elements like side seals, top seal and bottom seal.
There is sealing around the periphery of panel to restrict water passing through.
1.3 INSPECTION OF SFT GATE: a) Gate Travel The gate should be tested
for its smooth travel throughout in the groove, both up and down, without
appreciable sway.
b) No Undue Noises / Vibrations Gate shall not be subjected to undue pressure;
nor should any extra effort be needed to operate the gate. c) On load (when there
is water) there should be no undue vibrations in the gate and structure. In case
vibrations are noticed during operation of the gate, the reason there of should be
investigated. Until remedial measures are not taken, gates shall not be kept in
position at which vibrations are noticed. d) Free movement of the Gate Check
that the gate moves freely and without any obstruction in its guide. In case of any
problem, the alignment of embedded parts, properly level and align these guide
pads so as to maintain the required clearances between the gate guide and guide
pads. e) Greasing of clevis Check that there is no abnormal friction / jamming
due to no greasing of the bearing of clevis, in that case properly lubrication of such
bearings is done for their smooth operation. i) Replacement of Rubber Seals
Check that there is not much leakage due to the worn-out rubber seals, in such
cases; replace the worn-out seals with the new seals.
 1.4 MAINTENANCE SCHEDULE OF SFT GATE:
a) The gates shall be thoroughly inspected for cracks, defects or damages
periodically. A schedule of maintenance is proposed which may be adopted with
modifications, if required, to suit site conditions and use of gate. Any welds that
might have become defective should be chipped out and remade. Damaged nuts,
bolts, screws etc. should be replaced without delay.

b) All bottom corners should be cleared and accumulation removed.

c) The gate leaf should be properly cleaned and repainted as and when necessary,
according to paint specification mentioned in approved drawings.

Paint specification:
Ø One coat of zinc-rich primer be applied to give total dry film thickness of 75
Micron.
Ø Two coats of coal tar epoxy paint each coat of 150 microns. Total DFT not less
than 350 microns.

d) Rubber seals should be kept in one alignment. All nuts bolts fixing the seal to
the gate should be tightened uniformly. Seals if found damaged should be
replaced/repaired immediately to avoid excessive leakage.

e) Inspection of rubber seal and their replacement as per schedule the flat type seal
provided on bottom edges are replaced after three years and double stem type
rubber seals provided on top and both sides are replaced after 5-8 years depending
upon the conditions of seals.

f) Hoisting connection (clevis) on the gate leaf should be lubricated where

necessary and defects if any should be rectified.

g) All nuts, bolts, check nuts and pins of lifting devices should be checked
periodically.

h) All components should be greased and lubricated. Recommended and approved

oils and grease only should be used.

1.4.1 MONTHLY MAINTENANCE:

a) Operate the gate for its full height should be checked.

b) Leakage though stuffing boxes during gate operation to be checked.

c) Check all nuts and bolts for tightness and tighten them if loose.

1.4.2 QUATERLY MAINTENANCE:

a) Operate the gate for its full height should be checked.

b) Leakage though stuffing boxes during gate operation to be checked.

c) All bolts and nuts provided in stuffing boxes and Top cover shall be tightened.

d) Adjust / replace glands of stuffing boxes if leakages are found at local points.

e) Adjust / replace gasket of top cover if leakages are found at local points.

1.4.3 ANNUAL MAINTENANCE:

a) All the embedded parts, bonnet body and cover shall be checked for defects /
damages and shall be rectified wherever noticed and exposed parts shall be painted
for longer life.

b) The embedded parts and bonnet body shall be cleared for all girt, sand etc.

c) The clevis shall be lubricated and ensure for its movement.

d) Seal seating shall be inspected for leakages. Locations of excessive leakages

shall be recorded for taking remedial measures.

e) All bolts and nuts holding rubber seals shall be tightened. Adjust / replace seal if
leakages are found at local points.

f) The re-painting of the gates shall be carried out if required.

g) The inspection, testing and maintenance of the hoist shall also be carried out
periodically as per the maintenance manual.

h) Check all the welds for soundness and rectify defects if any.
 i) Clean all drain holes including those horizontal girders.

j) Check all nuts and bolts for tightness and tighten them if loose.

k) Check upstream face of skin plate for pitting, scaling and corrosion.
 l) Scale formation shall be removed, pitting shall be filled with weld and ground,
and Corroded surface shall be cleaned and painted. In case of gate not being raised
every quarter, these can be carried out in annual maintenance.

m) Adjust / replace glands of stuffing boxes if leakages are found at local points.

n) Adjust / replace gasket of top cover if leakages are found at local points.

IN ADDITION TO THIS, GENERAL MAINTENANCE OF VERTICAL GATE

SHOULD BE TAKEN AS PER IS 7718 : 1991 1.5 GENERAL
MAINTENANCE OF SFT GATE: 1.5.1 EVERY THREE YEARS:
a) Check seals for damage and alignment

b) Check seal bolts for damage

c) Check for damage to Top cover gasket;

d) Check for any damage to clevis bearing

e) Check for any painting damage

f) Functional issue of air release valve

g) Leakage issues of Stuffing boxes

1.5.2 EVERY SIX YEARS:

a) Skin plate joints if any

b) Splice joints if any

c) Horizontal girders
 d) Check clevis assembly for following: v Any breakage
v Jamming
v corrosion
v Misalignment

h) Check seal seats, seal tracks, side guides for the following:
v Any damages
v Corrosion
v Pitting
v Misalignment

i) Check Top cover for the following:

v For any welding cracks
v Bent or loose bolts and nuts
v Cracks in flanges where hydraulic hoist is seated
v Functional issue of air release valve
v Leakage issues of Stuffing boxes

. 1.6 LIST OF DRAWINGS FOR SFT GATE:

Sr. No. Description GMW DRAWING NO.

1 0.75 M [W] x 1.8 M [H] GMW-J.1097-BG-01

BONNET GATE
EMBEDDED PART
DETAILS

2 0.75 M [W] x 1.8 M [H] GMW-J.1097-BG-02

BONNET GATE BODY
PART DETAILS

3 0.75 M [W] x 1.8 M [H] GMW-J.1097-BG-03

BONNET GATE
DETAILS OF GATE
LEAF

4 0.75 M [W] x 1.8 M [H] GMW-J.1097-BG-04

BONNET GATE
RUBBER SEALING
ARRANGEMENT
 2.0 HYDRAULIC HOISTS AND POWER PACKS FOR SFT GATE:
TECHNICAL DATA OF HYDRAULIC HOISTS:
2.2 TECHNICAL DATA OF POWER PACK:
Sr. No. Description
1 Working pressure
2 Test pressure
3 Cushioning rod
side
4 Cylinder speed
5 Pull & push force
6 Operating fluid
7 Cylinder tube
8 Piston rod
9 Mounting
10 Connection with
gate
Sr. No. Description
1 Motor make
2 Type of motor
3 Motor HP
4 Pump
5 Motor and pump
6 Operating fluid
7 Solenoid coil
8 System fluid
9 Hydraulic tank
2.1
Data
: Rod side – 198 bar
Piston side – 159
bar
: Rod side - 297
bar Piston side –
239 bar
: 100 mm
: 0.5 m/min
: 65 MT
: VG32 / HLP32
: St 52
: AISI 431 (1.4057
SS)
: Flange mounting
: Clevis at rod end
Data
: C.G./Siemens/AB
B
: 3-phase Squirrel
cage induction
motor
: 15 KW and 1450
rpm
: 28 lpm and 198
bar
: Continuous Duty
(S1)
: VG32 / HLP32
: 220 V AC
: ISO-VG32 /
HLP32
: M.S. (IS2062 Gr.
B), 650 ltrs
2.3 DESCRIPTION OF HYDRAULIC CYLINDERS AND POWER PACK:
Hydraulic cylinders are positioned vertically inverted at top of bonnet gates. Each
cylinder has capacity to lift 65 MT, with a full stroke length of 2050 mm. Piston
rod is connected to the gate through a clevis. For opening and closing the gate,
pressurized oil from power pack will supplied to the cylinder and gate will be
actuated. Control Panel is provided for operation of gates from a centralized
location. Control panels are vertical type in IP54 execution for indoor use with
separate panel boxes. Panels are PLC based panels and provided with 4 sets of
controls and indication lamps. In addition, Ammeter, Voltmeter, Phase indicator,
Isolators, MCCB’s as per standards are provided. The circuit provides for all
required operational controls and interlocks for the individual gate operations and
also the necessary indications. 2.4 OPERATION OF SILT FLUSHING
TUNNEL GATE 2.4.1 GENERAL CHECKLIST BEFORE STARTING THE
OPERATION OF HOIST All the operations of Hydraulic hoists are controlled
through a control panel. Operator can operate the Hoist with the help of selector
switches and push buttons, provided on control panel. The following points may
be checked before starting operation: -
a) Ensure that all electric connections are made as per the wiring layout.

b) Fill the tank with clean & standard hydraulic oil.

c) Ensure that suction ball valve is in open position.

d) Run the motor on Inching to ensure that motor is running in clock-wise direction
when viewed from the fan side of the motor.

e) Pressure can be generated only when solenoid is energized.

f) On turning pressure knob clock-wise pressure can be increased, turn the knob
anticlockwise to reduce the pressure.
g) Ensure that system pressure do not exceed 198 bar.

h) Reading on the pressure gauge can be noted on pushing the knob of push to read
type gauge isolator.

i) By energizing respective solenoids as indicated in wiring diagram cylinder can

be forwarded or retracted at a time or simultaneously.

j) Solenoids namely Open and Closed, are for manual raising and lowering of the
cylinders using manual override feature.

k) Ensure all flow control valves fully closed (Fully screwed in) during start up &
then slowly open. This is necessary to avoid free falling of the load due to wrong
setting of the throttle.

2.4.2 GENERAL OPERATION OF HOIST

a) Start the hydraulic pump motor mounted on hydraulic power pack.

b) Wait for about ten seconds for stabilization of system.

c) Give the “HOIST UP” or “HOIST DOWN” command through the push button
continuously till you get the desired level of opening / closing of gate. After getting
desired level, immediately release the push button.

d) During above operation if the motor trips immediately release the gate operation
push button if pressed. Stop the supply to motor. Do the steps 1 to 3 using the other
standby pump in the power pack.

e) Check the positions of all gates for the desired opening (or) closing.
f) Stop the pump.
2.4.3 EMERGENCY OPERATION OF HOIST To close the gate in emergency
situation press the emergency close push button for the respective gate, this will
activate the solenoid valve making return path of oil from cylinder to tank. During
the course, running of pump is not needed. Due to gravity force gate closes
automatically. During power failure, respective solenoid valve can be activated,
mounted on power packs by pressing its rod through a pin. Hence the valve will
operate and gate close.
2.4.4 REMOTE OPERATION

Provision of remote operation is provided in the control panel. “HOIST UP”,

“HOIST DOWN” and “HOIST STOP” has been provide to accept commands.
Gate Fully Open, Gate Fully Close and Hoist Trip feedback is also provided for
Remote operation.
2.5 MAINTENANCE OF HYDRAULIC CYLINDEERS AND POWER
PACKS

2.5.1 MAINTENANCE OF THE HYDRAULIC CYLINDER

• Hydraulic cylinders are generally maintenance-free. Ensure the bearing points
(such as swivel bearings and articulated bearings) as well as the swivel pins.

• Check the entire system for leaks and for externally visible damage at regular
intervals

• Depressurize the entire system before opening it (e.g. when removing individual
components)

Seal change: seals and guides are wear parts. If internal or external leakage
reaches and unacceptable level, we recommend that you have the seals and
guides replace at our works (always have the complete seal kit replaced) as the
entire hydraulic cylinder is checked during disassembly
2.5.2 MAINTENANCE OF THE HYDRAULIC POWER PACK
Ø General Maintenance

v Electric Motors

Lubricate as recommended by the motor manufacturer.

v Filters

Change or clean as required or as indicated on filters supplied with visual

indicators. Make sure to check indicators shortly after start-up.
v Suction Strainers

Should be cleaned after 10 hours of operation initially and every 100 hours
thereafter. See appendices for cleaning instructions.
v Reservoirs -

Maintain oil level at all times. The oil should be checked after the first 100 hours
and verify that the class of oil meets the requirements of the pump being used.
Change the oil every 1000 to 2000 hours depending on the application and
operation environment.
Ø Recommended Spare Parts

Spare filter elements should be purchased with the power unit, and be available
during the start-up operation. Other spare parts may be required, and are a function
of the duty cycle of the hydraulic system, operation environment, and the
acceptable down time of the equipment. Please refer the list of recommended spare
parts on page no. 25 of this manual
Ø Preventive Maintenance
 • Filter Service

Filters must be maintained. The key to good filtration is filter maintenance. A

machine may be equipped with the best filters available and they may be
positioned in the system where they do the most good; but, it the filters are
serviced and cleaned when dirty, the money spent for the filters and their
installation has been wasted. A filter which gets dirty after one day of service and
is cleaned 29 days later gives 29 days of non-filtered fluid. A filter can be no better
than the maintenance provided.
• Maintenance Suggestions

1) Set up a filter maintenance schedule and follow it diligently. 2) Inspect filter

elements that have been removed from the system for signs of failure which may
indicate that the service interval should be shortened and of Impending system
problems. 3) Never return to the system any fluid which has leaked out. 4)
Always keep the supply of fresh fluid covered tightly. 5) Use clean containers,
hoses, and funnels when filling the reservoir. Use a filter cart when adding oil is
highly recommended. 6) Use common sense precautions to prevent entry of dirt
into components that have been temporarily removed from the circuit. 7) Make
sure that all clean-out holes, filter caps, and breather cap filters on the reservoir are
properly fastened.
8) Do not run the system unless all normally provided filtration devices are in
place. 9) Make certain that the fluid used in the system is of a type recommended
by the manufacturers of the system or components. 10) Before changing from one
type of fluid to another (e.g., from petroleum base oil to a fire resistant fluid),
consult component and filter manufacturers in selection of the fluid and the filters
that should be used. Also consult the publication “Recommended Practice for the
use of Fire Resistant Fluids for Fluid Power Systems” published by the National
Fluid Power Association. 11) GMW offers a Particle measurement system which
can be used to ascertain the condition of the system fluid.
• Maintaining Proper Oil Temperature

Hot oil in your equipment’s hydraulic system is one of the primary causes of poor
operation, component failure and downtime. Here are some pointers on
maintaining proper oil temperature. The oil in your hydraulic system was designed
for operation within a specified temperature range. You may be able to run it at
hotter temperatures for short periods of time, intermittently, without adverse
effects. If you run continuously with oil that’s too hot, your equipment will operate
poorly causing key component failure and machine downtime.
“Hot oil” is a relative term. In most cases, 40°C at the reservoir is considered an
ideal operating temperature. Always take an oil temperature reading at the
reservoir, not at a component or any of the piping. How can you keep your
equipment’s hydraulic system from running too hot?
1) Set up a regular schedule for checking the oil temperature, appearance, smell
and feel. Change oil as recommended.

2) Be prompt about removing, checking and repairing or replacing valves, pumps

or other components that are running hot.

3) If relief or flow-control valves are running hot, check and adjust their settings.

4) Break in new components gradually. New, close fitting parts expand at different
rates, and are especially prone to seize when they get too hot.

5) Start a cold pump motor on hot oil by jogging just enough to draw the hot oil
into the component. Then wait a few minutes to allow the temperature to equalize
in all the pump’s parts. Repeat until the temperature on the outside of the pump is
the same as that on the piping.

6) Keep your equipment clean. A thick layer of dirt acts as insulation. It will
prevent the hydraulic system from getting rid of heat.
 7) On hot days, and in hot climates, check and change the oil more frequently. Be
sure to use an oil recommended for hot weather operation

• Measuring Oil Temperature

There are several ways to check the temperature of the oil. The best, most accurate
method is by means of a thermometer. On some machines, this is mounted on the
reservoir. Make it a habit to check the thermometer periodically, after the
equipment has been running for more than an hour continuation.
• Isolating Trouble-Spots

To determine which components are “running hot” and overheating the oil, feel
the outlet fittings and lines at the valves, pumps and motors. If the oil temperature
is normal going into a component but hot coming out, that could be one of the
potential problem areas. A sticking valve can cause excessive heat. If a spool does
not return promptly to the neutral position, the pump flow will be dumping
continuously. This builds up heat rapidly. a relief valve is set too low, part of the oil
will be dumped across the valve with every cycle. This too, generates excessive
heat. Even when all valves are set properly, they may not be operating well because
of worn orifices or seals. Always remove and check the hot components first.
• Check Oil Samples Periodically
 Checking oil temperature periodically is good preventive maintenance. So too is
the practice of periodically siphoning an oil sample from the reservoir, and
comparing it with a sample of clean, new oil. Oil that has been running too hot will
look darker and feel thinner than new oil. It will also smell burned. Normally it
will contain more contaminants, because hot oil leads to accelerated wear of
component parts. G. Troubleshooting a. Dirty Oil 1) Components not properly
cleaned after servicing. 2) Inadequate screening in fill pipe. 3) Air breather left off.
(No air breather provided or insufficient protection of air breather). 4) Tank not
properly sealed. 5) Pipe lines not properly covered while servicing machine. 6)
Improper tank baffles not providing settling basin for heavy materials. 7) filter
dirty or ruptured. b. Foaming Oil 1) Tank line not returned below fluid level. 2)
Broken pipe. 3) Line left out between a bulkhead coupling and the bottom of the
tank after cleaning. 4) Inadequate baffles in reservoir. 5) Fluid contaminated with
incompatible foreign matter. 6) Suction leak to pump aerating oil. 7) Lack of anti-
foaming additives. c. Moisture in Oils
 1) Cooling coils not below fluid levels. 2) Cold water lines fastened directly
against hot tank causing condensation within the tank. 3) Soluble oil solution
splashing into poorly sealed tanks or fill pipes left open. 4) Moisture in cans used
to replace fluid in tanks. 5) Extreme temperature differential in certain
geographical locations. 6) Drain not provided at lowest point in tank to remove
water collected over possibly long operating periods. d. Overheating of System
1. Relief valve set too close to compensator pressure setting.
2. Continuous operation at relief setting.

a. Stalling under load, etc. b. Fluid viscosity too high or too low.
3. Excessive slippage or internal leakage.

a. Check stall leakage part pump, motors and cylinders. b. Fluid viscosity too low.
4. Reservoir sized too small

5. Case drain line from pressure compensated pump returning oil too close to
suction line.

a. Re-pipe case drain line to opposite side of reservoir baffling

6. Pipe, tube or hose I.D. too small causing high velocity.

7. Valving too small, causing high velocity

8. Improper air circulation around reservoir.

9. System relief valve set too high

10. Power unit operating in direct sunlight or ambient temperature is too high.

e. Foreign matter sources in circuit 1) Pipe scale not properly removed. 2)

Sealing compound (pipe dope, Teflon tape) allowed to get inside fittings. 3)
Improperly screened fill pipes and air breathers. 4) Burrs inside piping. 5) Tag ends
of packing coming loose. 6) Seal extrusions from pressure higher than compatible
with the seal or gasket. 7) Human element... not protecting components while
being repaired and open lines left unprotected. 8) Repair parts and replacement
components not properly protected while stored in repair depot. (Rust and other
contaminants). f. Troubleshooting Pumps
Ø Pump makes excessive noise

1. Check for vacuum leaks in the suction line. (Such as leak in fitting or damaged
suction line.)

2) Check for vacuum leaks in the pump shaft seal if the pump is internally drained.
Flooding connections with the fluid being
pumped may cause the noise to stop or abate momentarily. This will locate the
point of air entry. 3) Check alignment with drive mechanism. Misalignment
will cause premature wear and subsequent high noise level in the operation.
4) Check manufacturer’s specifications relative to wear possibilities and
identification of indications of wear as high operating noise level, etc 5)
Check compatibility of fluid being pumped against recommendations. 6)
Relief or unloading valve set too high. Use reliable gauge to check operating
pressure. Relief valve may have been set too high with a damaged pressure
gauge. Check various unloading devised to see that they are properly
controlling the pump delivery. 7) Aeration of fluid in reservoir (return lines
above fluid level). 8) Worn or sticking vanes (vane type pump). 9) Worn cam
ring (van type pump). 10) Worn or damaged gears and housing (gear pump).
11) Worn or faulty bearing. 12) Reversed rotation 13) Cartridge installed
backwards or improperly. 14) Plugged or restricted suction line or suction
strainer. 15) Plugged reservoir filler breather. 16) Oil viscosity too high or
operating temperature too low. 17) Air leak in suction line or fittings may
cause irregular movement of hydraulic system.
18) Loose or worn pump parts.
19) Pump being driven in excess of rated speed. 20) Air leak at pump shaft seal.
21) Oil level to low and drawing air in through inlet. 22) Air bubbles in
intake oil. 23) Suction filter too small or too dirty. 24) Suction line too small
or too long. 25) Pump housing bolts loose or not properly torqued.
Ø Pump failure to delivery fluid

1) Low fluid level in reservoir. 2) Oil intake pipe suction strainer plugged. 3) Air
leak in suction line and preventing priming. 4) Pump shaft turning too
slowly. 5) Oil viscosity too high. 6) Oil lift too high. 7) Wrong shaft rotation.
8) Pump shaft or parts broken. 9) Dirt in pump. 10) Variable delivery pumps
(improper stroke).
Ø Oil leakage around pump

1) Shaft seal worn. 2) Head of oil on suction pipe connection – connection leaking
3) Pump housing bolts loose or improperly torqued. 4) Case drain line too
small or restricted (shaft seal leaking).
Ø Excessive pump wear
1) Abrasive dirt in the hydraulic oil being circulated through the system. 2) Oil
viscosity too low. 3) System pressure exceeds pump rating. 4) Pump
misalignment or belt drive too tight. 5) Air being drawn in through inlet of
pump.
Ø Pump parts inside housing broken

1) Seizure due to lack of oil. 2) Excessive system pressure above maximum pump
rating. 3) Excessive torqueing of housing bolts. 4) Solid matter being drawn
in from reservoir and wedged in pump. g. Troubleshooting Solenoid Valves
Ø Solenoid failures
1) Voltage too low. If voltage is not sufficient to complete the stroke of the
solenoid, it will burn out the coil.
2) Voltage too high. Excessive voltage can also burn out coils.
3) Signal to both solenoids of a double solenoid valve simultaneously. One or both
of the solenoids will be unable to complete their stroke and will burn out.
(Make certain the electrical signal is interlocked so that this condition cannot
exist).
4) Mechanical damage to leads. (Short circuit, open connections, etc.)
5) Tight spool or other mechanical parts of the valve being actuated can prevent the
solenoid from completing its stroke and subsequently burning out.

6) Replacement springs too heavy in valve. Overloads solenoid and shortens

life.
7) Dirty contacts may not supply sufficient current to solenoid to satisfy inrush
demands. 8) Low voltage direct current solenoids may be affected by low
battery capacity on cold mornings directly after starting cold engine. (DC)
9) Long feed lines to low voltage solenoids may cause sufficient voltage drop to
cause erratic operation.
 No.
MAINTANANCE
Of SCHEDULE STANDARD MAINTENANCE SCHEDULE
Daily 100 150 200 250 300 350 400 500 550
Hour
s HEAVY DUTY MAINTENANCE SCHEDULE
HYD I
RAU
LIC
No. Daily 100
FLUI 150 200 250 300 350 400 500 550
Of
D
Hour
LEV
Es
HYD
HYD I R
RAU
RAU
LIC
LIC
FLUI
FLUI
DD
LEV
REM R R R R
E
OVE
HYD
CON R
RAU
DEN
LIC
SED
FLUI
MOISTURE
D
CHE I
REM R R
CK
OVE
FOR
CON
LEA
DEN
KS,
SED
KIN
MOI
KS,
STU
ETC.
RE
HYD I R R R R
RAU
LIC
FLUI
D
FILT
ER
RELI I I I I I
EF
VAL
VE
SET
TIN
GS
 RARE USING SPARES
I - Inspect (In dusty conditions or when airborne debris is present) R- Replace H.
List of SR. NO.
Recommended SPARES
Spare Parts There QTY.
are two types of spares: A) Fast Moving
Spares B) (1)Rare using sparesDirection Control Valve 01 No.
(2) Pump 01 No.
(3) Pressure Gauge 01 No.
(4) Relief valve 01 No.

FAST MOVING SPARES

SR. NO. SPARES QTY.
(1) Suction Strainer 01 No.
(2) Elements for Return line 01 No.
filter, Pressure line filter
and Suction Filter.
(3) Seal kit for Pump 01 No.
(4) Seal kit for Relief valve 01 No.
(5) Seal kit for Flow control 01 No.
valve
(6) Seal kit for Hyd. Cylinder. 01 No.