Keeping logs of these tests, trained technicians detect early signs
of ring, bearing and valve wear. They reportedly can pinpoint with
great accuracy signs of pending trouble by watching increasing signs
of wear of certain engine parts through elements showing up in the
laboratory analysis,

Quickly reporting its findings to the maintenance department, the com-
pany advises remedial action and keeps a record of the laboratory
history of each engine being sampled.

In removing the guesswork from equipment maintenance procedures,
the company reports that big equipment operations are not only re-
ducing the number of major breakdowns through laboratory control,
but are keeping equipment on the job longer. They report that a con-
servative cost analysis shows that every dollar spent for this service
saves $10 in maintenance costs.

HOW TO MAINTAIN HYDRAULIC SYSTEMS

(Reprinted from the September 1961 issue of WESTERN CONSTRUC-
TION with the permission of the Editor)

It can probably not be said enough nor heard by enough people that
trouble-free operation of any hydraulic system depends on clean oil.
Almost all hydraulic components depend upon the hydraulic fluid itself
for their lubrication, Hydraulic systems on construction equipment
are particularly vulnerable to becoming contaminated due to the atmos-
phere in which they operate. Heavy dust and temperature changes
which cause water to condense in the systems are the primary cause of
contamination and subsequent failure through abrasive wear of internal
parts and packing of the hydraulic components.

Manufacturers of hydraulic components take many steps to eliminate
contamination of the units at the time of shipment, equipment manu-
facturers take many precautions in the design and assembly of the
hydraulic system on the vehicle, but in too many cases the proper pre-~
cautions for the elimination of contamination in the system end when
the equipment is put into use by the contractor. Most well designed
hydraulic systems utilize strainers in the inlet line to the pump and an
in-line filter at some other point in the hydraulic system. Many hydrau-
lic systems in construction equipment utilize a circuit which requires
that the oil reservoir breathes to the atmosphere. The breather is
usually fitted with a filter to screen out dust and dirt particles as the
air enters when the oil level is lowered by the operation of the circuit.
Some circuits eliminate this source of contamination by a slight pres-
surization of the reservoir by compressed air. It is important to know

17


Photo No. 3

Photo No. 4

Photo No. 5

by utilizing an indicator
arm riding along a taut
wire cable set on steel
grade stakes, Photo-
graphs No. 1 and 2.

The finished excavation
provides a lateral hav-
ing a 24-inch bottom,
1-1/2:1 side slopes, and
a 42-inch depth. The
subgrade prepared for
lining is shown in Photo-
graph No. 3. The sub-
grade guided slip-form
used in the placement

of the concrete and re-
modeled for the work by
the Conservancy District
is shown in the back-
ground.

Concrete is supplied to
the slip-form by transit-
mix trucks having a ca-
pacity of 4 cubic yards
and also purchased for
the lining operation by
the Cons ry Dis-
trict, hN
The tr
are cha)
servancy Di
able batchi
graph No.

ict's port-
plant, Photo-
5, and the slip
form is a ndard type
commercially available,
but remodeled by the
District to better fit con-
ditions on the project.

Modification of the slip-
form has consisted of
installing the reversible
direction screw conveyor
shown in Photograph No.
6, the spading equipment
shown in Photograph No.
7 on each side of the con-
crete hopper to distribute
and consolidate the fresh
concrete at the end of the


Automatic push-button controlled hydraulic systems are now being
used where a standard sequence of events must take place such as

in a refuse collecting truck. In this system, when the refuse hopper
is full, the operator merely pushes a button, the hopper raises, dumps
into the main body of the truck, the refuse is compacted, the com-
pacting cylinder returns to normal position and the hopper is lowered
and tipped to its normal position, whereupon the system remains idle
until the operator again pushes the button.

Many manufacturers of construction equipment would like to elimi-
nate, if possible, the bulky and costly torque converters and trans-
missions, final drives, rear axles and differentials if possible
through the use of a primary hydrostatic drive. Such a system would
generally consist of the vehicle engine driving a high-efficiency hy-
draulic pump converting the mechanical energy of the engine into
hydraulic energy. This hydraulic energy would then be piped to hy-
draulic motors at the wheels or track sprockets. With such a system
there would be no mechanical connection between the engine and the
wheels. With the necessary control valves it is conceivable that
each wheel could be operated independently when necessary.

As progress continues in hydraulics we are sure that the day is not
too far off where primary hydrostatic drive units will predominate
as a method of vehicle propulsion.

REMOVABLE CAR WARNING LIGHTS

(Reprinted by permission of GRIST, November /December 1961
issue, a publication by the National Conference on State Parks,
Washington, D.C.)

Those flashing red warning lights on a park car are mighty impor-
tant when the car is in patrol service, but what about the times when
the car is on other duty and the lights look out of place? Wayne B.
Cone, Chief; Park Ranger of Badlands National Monument, South
Dakota, did some thinking about this problem and came up with a
practical solution--an easily removable bracket which will hold a
flashing light in place solidly while needed, but which can be taken
down in a few minutes.

A drawing of the removable car warning light assembly is shown in

a drawing on the following page. With several sets of the brackets,
simple wiring, and the necessary small holes in the door posts of the
cars or trucks, a number of vehicles can be set to go into emergency
or patrol service with flashing lights, or to convert to service without
such lights.

21



the anodes of this type
with an adjustable chain
suspension, where it is
being used to protect a
bypass gate in the All-
American Canal head-
works. The detail of
the connections and
method of suspension are
shown. The anodes are
2 inches in diameter,

60 inches long, and weigh
about 48 pounds. Their
cost continues to be
about $19 per anode,

and greater mechanical
strength and longer life
have contributed to their
selection over other
materials for use on the
All-American Canal
System.

Desilting Works

As mentioned in the pre-
vious release, the desilt-
ing works for the All-
American Canal are com-
posed of three large

Photo No. 2 basins, with each basin

divided in half by an

influent channel. The south half of one of the dewatered basins is shown
in Photograph No. 2. Also shown are the clarifiers and the anodes and
supporting line of the cathodic protection system. In addition, there
are numerous underground sludge lines, waterlines and metal conduits.
The desilting equipment was exposed to the weather for about 9 years
before being put into service. The equipment was submerged for about
3 years before experimentation with cathodic protection was begun.

The 72 clarifiers installed in the desilting basins have a total sub-
merged steel surface area of about 200,000 square feet. The original
coating on the desilting basin clarifiers was a coal-tar enamel. In
1952 the coating was judged to be in fair condition with bond to the
steel also fair. Extensive cracks were noted but there was no exten-
sive corrosion. The metal surfaces continue to be in a satisfactory
condition with cathodic protection, although the cost of protection

for the year 1961 was less than $2,000, including about $500 for
power. This amounts to about 1 cent per square foot per year for

the metalwork being protected. As pointed out in the previous article,


where your oil strainers and filters are located on the machine and
to instigate a program for periodic cleaning or replacement of the
filter elements.

Another source for contamination in a hydraulic circuit is any leak
which may occur. All leaks or seepages of oil not only waste hydraulic
fluid but also provide a source for entry of dirt. Seals and wipers
around piston rods and hydraulic motor shafts should be kept in good
condition and replaced when necessary for these areas also provide

for the entry of dirt, water, and air.

A Suggested Program

No set rule can be established which will govern every situation for
the periodic preventive maintenance functions to be performed ona
mobile equipment hydraulic circuit because of the varying conditions
under which such equipment operates. Many contractors spray vast
quantities of water to reduce dust while in other areas this is not
possible or practical. A good minimum set of rules for preventive
maintenance to follow would be:

1. A complete change of hydraulic fluid and replacement with new
fluid annually during the normal idle time of the equipment. A
breakdown of equipment while in operation is-always extremely
costly.

2. Immediate reporting or repair of any oil leak when noticed.

3. A program established for the replacement of filter, car-
tridges, strainers and air breather assemblies on a schedule
which is proportionate to the air contamination in which the
equipment is operating. As a maximum, this period should be
no longer than 1,000 hours and as mentioned previously, the
minimum as local conditions dictate. Oil filter elements should
be inspected weekly.

4. Check oil level weekly.

5. Report and/or correct any strange noises coming from the
pump.

Most of us change the oil in our automobile engines at every 2,000
or 3,000 miles and periodically change our engine oil filter, but

how often is the hydraulic power steering oil changed or even the

oil level inspected? The oil in the hydraulic system may even-
tually break down through heat generation in the system even though
there were the unlikely situation of no contamination in the system.
When a hydraulic oil breaks down through heat, it forms varnish and
resinous substances on the moving parts of the hydraulic components

18




most versatile yet devised and hydraulics, even in its high degree
of development currently, is an infant compared to the giant we ex-
pect of it in the future.

As the art of hydraulics progresses today and advances in the future,
the basic principles will not change, but we can expect some dis-
tinct changes in the components used. Many trends are apparent to-
day which indicate the future complexion of hydraulics on mobile con-
struction equipment.

One significant trend is the use of higher pressures on mobile equip-
ment. The great majority of hydraulic systems on machine tool ap-
plications operate at, or below 1,000 psi, and in contrast to this,
mobile equipment hydraulic systems currently operate in the major-
ity of cases, in the range of 1,500 to 2,000 psi. Pumps capable of
operating at higher pressures, in the range of 3, 000 to 4, 000 psi,
are being used in increasing numbers. A majority of these units are
specially designed high pressure gear pumps or piston type pumps.

The amount of power transmitted by the hydraulic system is directly
proportional to the pressure and to the volume (gpm) of oil pumped,
therefore the power transmitted by a hydraulic circuit can be in-
creased by increasing one or the other, or both. In many cases it
is being found advantageous to increase the pressure since with this
approach the size of the hydraulic lines, valves, cylinders and in
some cases, the pump can be reduced. While cost savings cannot
always be realized by going to high pressures, usually the cost of
the hydraulic system is comparable to a low-pressure system while
the additional benefits of space and weight saving are realized.

Another significant trend in mobile equipment hydraulics is a pro-
gression from the relatively simple pump, manual control valve,
cylinder circuit for power transmission to more complex semi-
automatic or automatic circuits. These automatic circuits generally
employ a control circuit to actuate or operate the power circuit. The
control circuit can be pneumatic, hydraulic or electric and could be
referred to as the "brains" while the power circuit is the "muscle"
for doing the work. No, hydraulic service men in the future will not
need to be doctors, but apparently some training in more complicated
hydraulic circuits and electrical systems and components will be
necessary.

Another significant current trend is the use of hydraulics as a means
of propelling vehicles. For a number of years many small vehicles
have been provided with a traction drive through the use of hydraulic
motors but currently larger vehicles are progressing towards, or
using, hydraulics in the vehicle propulsion system. Some earth-
moving equipment is currently using hydraulic motors as booster
drives which supply the extra tractive effort only when it is required,
the vehicle being equipped with its normal transmission and final
drive system from the engine.

20


1963. With its own equipment now available, the District plans to
continue the lining program, placing as much as possible during
the non-irrigation season. The present program is one of taking
care of the more serious seepage problems where adjacent lands
are being damaged by water from unlined laterals.

Further information on the lining program can be obtained by
writing Mr. Sanford Caudill, Manager, Arch-Hurley Conservancy
District, Tucumcari, New Mexico.

CANT HOOK BECOMES
A BEAD BREAKER

(Reprinted by permis-
sion of GRIST, Novem-
ber/December 1961

a publication by the
National Conference on
State Parks, Washington
D.C.)

If you keep a cant hook on
hand for moving logs, you
have on hand an ideal tool
for breaking the bead of a
tire away from the rim.

It works almost as well

as one of those fancy bead-
breakers bought by service
stations,

Someone at Bald Mountain
Recreation Area in Michigan
discovered this new use for
cant hooks and let GRIST
know about it.

*

15



the lead wire connection in epoxy resin using a plastic tube mold; and
by providing a coke breeze backfill for the entire anode and its connection.

The second experience was in the new high-silicon, cast iron anode
system for the left barrel of New River Siphon. In this instance, the
individual anodes had been secured to the plastic-covered catenary cable
by wrappings of tape at each end and by a stainless steel clamp. Sub-
sequent inspection revealed the failure of a number of these clamps
caused by chlorine gas entrapment.

Effects of Cathodic Protection on Reinforcing Steel in Concrete

It has been noted in determining the correct protective current for
various structures that the amount of reinforced concrete in a given
structure has a noticeable effect on the final current requirement.
With this in mind, tests are being conducted at the South Alamo turn-
out on the All-American Canal for the purpose of determining the ef-
fects of cathodic protection currents on embedded reinforcing steel in
concrete. These tests were initiated in January 1961.

Two types of tests are being conducted as follows:

1. To determine if protective current will cause damage to an
ungrounded bar of reinforcing steel in concrete.

2. To determine if protective current will cause deterioration of
the bond between concrete and reinforcing steel.

After 18 months, a test cylinder receiving an average of 66 milliamperes
per square foot was removed and broken open. In this time no corro-
sion was noted on the ungrounded bar and no visible deterioration of
concrete bond to steel was evident on the bar under protection. The
tests on the remaining cylinders will be continued.

Conclusions

We appreciate the efforts of L. R. McGlocklin, C. H. Youngstrom, and
O. L. Fudge of the Imperial Irrigation District for the excellent sum-
maries of the experience with cathodic protection of submerged metal-
work. The protection being afforded such metalwork undoubtedly has
decreased metal maintenance. We shall follow the further field exper-
ience and studies with interest and will prevail upon them to provide

us with additional information.

If further detail is desired, address correspondence to Mr. Robert F.
Carter, General Manager, Imperial Irrigation District, El Centro,
California.



not replaced, was
$1,116 for labor

and $896 for parts.

The total cost of

$2,012 amounts to

an investment of about
11 cents per square foot
of area to be protected.
The annual cost for cur-
rent is negligible,
amounting to about $2.45
for 98 kwh of power, or
the equivalent of burn-
ing a 60-watt light bulb 4 or 5 hours per day for 1 year. Subsequent
annual inspections have shown the dissipation rate of the high-silicon,
cast iron, anodes to be practically nil.

Photo No. 4

District experience continues to show that the protection afforded the
siphon barrels by either the impressed current system with cast iron
anodes orthe galvanic
system with magnesium
anodes is equal and
sufficient. A typical
view of the excellent
protection afforded is
shown in Photograph
No. 5. However, be-
cause of the lower main-
tenance cost and longer
life expectancy of the
cast iron anode, and
considering that the
initial cost for material
and installation were
nearly the same for
both barrels, the Dis-
trict believes the cast
iron anode system will
prove to be the most
economical,

Photo No, 5

Inspections

As mentioned in the previous article, a typical impressed current
cathodic protection system employs a disc-type or plate-type rectifier
for converting the usually available alternating current to direct
current. The rectifier unit, Photograph No. 6 contains a transformer
to reduce the input voltage to 20 volts or less. Tap-changing links

or rheostats to adjust the voltage are provided, as well as fuses or
circuit breakers to protect the equipment from overload. In addition,
the rectifier unit contains a voltmeter and an ammeter for convenient
routine inspection by maintenance personnel and a record card has been
provided for noting readings and condition of the system each month.

4


the estimated cost of sandblasting and recoating this complicated
machinery would be approximately $300, 000.

Also as previously reported, nurnerous failures had occurred in the
sludge lines, waterlines, and metal conduits under the desilting ba-
sins. Electrolysis was determined to be the prime cause of trouble
and, as a result, the protective cathodic system was expanded to in-
clude anodes buried in the basin floor. There now have been no addi-
tional failures in the underground piping for the past 5-1/2 years.

New River Siphon

Some changes have been made in the cathodic protection system of the
New River Siphon, which consists of two steel barrels, each 15 feet

6 inches in diameter with an overall length of 476 feet. Water flowing
through the siphon has a velocity of about 7 feet per second.

Two types of anodes and systems originally were used to protect the
siphon barrels. The anodes in the right or west barrel is magnesium
and depends on galvanic action between the magnesium of the anode and
the steel barrel for cathodic protection.

Regulation of the current is provided by an external resister. New
sections of magnesium rods are spliced in as required. About 34 pounds
of new magnesium rod are required per year. At 96 cents per pound,
the cost for rod replacement is about $33.

The protection of the left or east barrel originally consisted of an
impressed current system and a 7/8-inch-diameter steel rod anode,
with current provided by a rectifier. This anode lasted from 1951 to
1959, when it was replaced by a commercial type series of high-silicon,
cast iron anodes, 2 in-
ches in diameter and

9 inches in length,
strung horizontally at
4-foot centers, Photo-
graph No. 3.

Photograph No. 4, on
the following page, is
a detail view of one
of the anodes secured
to the steel cable cat-
enary which has been
enclosed in a plastic
tube. The cost of the
new installation, ex-
clusive of steel cate-
nary cable and cable
supports which were

P-212-0-40309

Photo No. 3


MASTER MECHANIC

(Reprinted from the July 1961 issue of WESTERN CONSTRUCTION
with the permission of the Editor)

Significant reductions in maintenance costs are resulting from use of
regular laboratory analysis of lube oil for big equipment fleets. A

firm in California discussed the techniques of laboratory control of
maintenance operations and the reasons for these maintenance depart-
ment cost savings during a talk before the Los Angeles chapter of EMSA,

It was pointed out that in the past, engines and equipment operated

until they broke down, Then, with the introduction of wide scale preven-
tive maintenance programs, overhaul programing oftentimes became

too conservative. Engines were being overhauled more frequently than
necessary.

But with a laboratory's ability to detect engine conditions and plot
trends, maintenance can be adjusted to the needs of individual engines.
The savings payoff comes in the form of:

1. Reduction in equipment failures caused by unpredicted wear
in the engine or hydraulic system.

2. Safe extension of oil and filter changes over longer periods.

3. Selecting oil and air filters best suited for different operating
conditions and their use over longer periods of time.

4. Component replacement and repairs before their failure leads
to major breakdown.

5. Maintenance can be programed safely, keeping key equipment
on the job longer, leveling of manpower needs in the maintenance
department.

Lube oil analysis, according to a member of the company, is practical
with any hydraulic system, internal combustion engine, transmission
or differential. It is being used by most large oil companies, railroads
and engine companies.

Using samples taken by the maintenance department of the firms serv-
iced, the California firm performs direct reading spectrometer
analyses and physical tests of lubricating oil for controlled mainte-
nance, The spectrometer measures the amount of trace elements in
the oil--elements indicating component wear that show up in chemical
solution and are measured in parts per million. The remainder of the
oil is analyzed for viscosity, flash point, fuel and water dilution, acid,
content, sludge and other physical properties.

16



Photo No. 8

6


Warning light-----~

Sheet metal screw.

Bar aluminum----

Connector.__

_--7Aluminum bar
ee
@*e

Bolt----.. _-Nut
ig@coocano} —r .

Rubber cushion-~~

_---Hold down spring
Attach to vehicle here-----___

REMOVABLE CAR WARNING LIGHTS

22



OPERATION AND MAINTENANCE
EQUIPMENT AND PROCEDURES
RELEASE NO. 45
July, August and September 1963
Late
=
=
—
=
[——]
—)
=
a.
=
a :
C2 P257-D-37612
=

CONTENTS

Cathodic Protection--A Supplementary Report
Ten Cents, Thirty Minutes--A Sign
Safety Lock for Fuel Line Valves

Tucumcari Project Concrete Lateral Lining Program
Cant Hook Becomes a Bead Breaker

Master Mechanic

How to Maintain Hydraulic Systems
Removable Car Warning Lights



To get the effect of roundness on such letters as S and O, cut the
corners of the squared tape on a diagonal, with the blade.

Unless the sign is to be used for only a few days, coat it with lacquer
or plastic spray. If it is to be installed on a post which would leave
the standard side visible, cover that side with plywood.

Such a sign takes 10 cents worth of materials (not including the
standard sign used as background) and 30 minutes or less of your
time. When it has served its purpose, it can be restored to the orig-
inal condition simply by stripping off the tape.

One important advantage to this method of temporary sign making is
that the end product looks professional.

SAFETY LOCK FOR FUEL LINE VALVES

(Reprinted by permission of GRIST, November /December 1961
issue, a publication by the National Conference on State Parks,
Washington, D.C.)

It will soon be time to light up space heaters, gas and oil burners,
and other types of fuel-fed heating devices. Many are thermostati-
cally controlled through pilot flames and the continuous burning of
the pilot is essential to safety and efficiency. Tampering with fuel
line valves, often unintentional, might cause the shutting-off of the
pilot flame. This can be eliminated by using a simple idea sub-
mitted by Ranger Doyle of Waterloo State Recreation Area, Michigan.

As the drawing shows, you simply drill a 1/8-inch hole through the
valve handle, put a wire through the hole, tie it around the pipe or
tubing, twist and cut off the loose ends. The valve, open when the
handle parallels the fuel line, is held in this position and cannot be
moved accidentally to the closed position.



TEN CENTS, THIRTY MINUTES--A SIGN!

(Reprinted by permission of GRIST, November /December 1961
issue, a publication by the National Conference on State Parks,
Washington, D.C.)

If your park shop has on hand some standard road signs but needs
some special lettering, one of the standard units may be easily con-
verted into a clear, professional-looking special version if you use
the method worked out by Phillip R. Iversen of Grand Canyon
National Park. The picture shows a comparison--''Winding Road"

is a standard sign purchased as such; ''School Zone" is a special,
prepared on the back of a ''Winding Road" sign by the Iversen system.

To follow Phil's method, all you need is some paint thinner or simi-
lar nonoily liquid, a roll of black plastic electrical tape, a single-
edge razor blade, some clear lacquer or plastic spray, a T-square
or drafting triangle, and a pencil.

First, clean with paint thinner the reverse side of a standard sign,
selected for the color and size you need. Then make light parallel
lines, their distance apart corresponding to the letter height you
want. Block in the letters in pencil. (Phil says you can skip this
step as you gain experience.) Next, lay the edge of the square or
triangle along the outer vertical edge of the first letter to serve as
a guide as you apply a strip of tape a little longer than the side of
the letter. Place the entire cutting edge of the razor blade firmly
where you want the tape to end, then use a slight sawing motion to
cut it straight and clean, removing the excess tape. If the letter
has horizontal lines, as in E, F, or L, start the horizontal at the
outer edge of your vertical piece, leaving no gap.


Additional Installations

Since publication of the pre-
vious article, the District
installed in 1960, a cathodic
protection system for three
major check structures on
the East Highline Canal,
providing anodes both up-
stream and downstream from
the radial gates. A typical
installation is shown in Photo-
graphs No, 7 and 8 on the
following page. These struc-
tures have a total of 17 radial
gates about 12 feet wide by

10 feet high. The total cost
including materials, labor,
transportation and miscel-
laneous was $2,452 or

$144 per gate.

The electric current con-
sumed for each of these

check structures is at the rate
of about 11 watts at 5.5 volts
and 2.0 amperes, Assuming
50 percent efficiency, this
would be at the rate of 22 watts
for a total of 193 kwh per year
Assuming a cost of 1.8 cents
per kwh, the annual power cost
for a six-gate structure would be only $3.37 or 58 cents per gate.

Trouble with Chlorine Gas

Chlorine gas is generated by the positive current flowing from an anode.
The District has learned that a wrapping or covering on an impressed
current anode tends to trap the chlorine gas, which is highly corrosive
to the anode.

The first experience was with the cast iron anodes buried horizontally

in the desilting basin floor. In an attempt to provide a waterproof con-
nection, the lead wire connection and head of the anodes were taped in

the normal manner and wrapped with linen covered by a bitumastic com-
pound. Early failures lead to the discovery of the deterioration caused by
the entrapment of chlorine gas. Excavated sand had been used to backfill
the anodes in the original installation; however, this too, tended to retard
the dissipation of chlorine gas. The condition was corrected by encasing


causing them to malfunction by sticking, if not locking completely.
When we complicate this by the addition of abrasive dust and dirt
wearing away the fine finishes and seals of valves, plus the rusting
of springs and finished surfaces by small particles of water carried
in the oil, it should be readily understood why the maintenance of
clean oil is an essential to a trouble-free hydraulic system.

When servicing is required on a hydraulic system and a component
must be replaced, it should be done under the most ideal conditions
possible, preferably in a maintenance garage. When a hydraulic
system is disassembled, or even one line removed, the interior of
the system is exposed to contamination and all possible precautions
must be taken to eliminate the introduction of dirt, pipe joint com-
pound, or any other material foreign to the system.

A Horrible Example

An interesting incident which occurred some years ago concerned
an equipment operator who was complaining bitterly about the hy-
draulics on his equipment. The pumps on the system would not last
more than 2 weeks to a month, his valves seemed to stick too often,
and oil was added quite often because of some leaks in the system.
Upon making a visit to this equipment user, we discovered a situa-
tion which I thought could never happen in this age of enlightenment.
It was true--his pumps were wearing out at an extremely rapid rate
and his valves were sticking but it was not the fault of the pump or
valve design or application, for the equipment manufacturer had in-
stalled an efficient system. This equipment user did have a few
leaks and, as a result, the reservoir oil level went down. Rather
than repairing the leaks developed on the system and having proper
maintenance performed periodically, the user added oil to the res-
ervoir. He did not add hydraulic oil, however, for this seemed like
a great extravagance. On the contrary, crank case oil which was
drained from the equipment's engines was added.

Further, since the inlet strainers in the reservoir seemed to be con-
tinually clogging up and causing strange noises in the pump, these
were left off. Perhaps it is not necessary to finish this story but
after the hydraulic systems were drained and flushed with clean hy+
draulic oil, all components of the system disassembled and cleaned
and the filter elements replaced, the system filled with clean and
proper hydraulic fluid, and the preventive maintenance performed

on the system, the equipment user once again received good hydraulic
operation and normal pump life.

Significant Trends
It is important to remember that a hydraulic power transmission sys-

tem requires as much consideration as the other power transmission
systems of your vehicles. Hydraulic power transmission is one of the

19



CATHODIC PROTECTION--A SUPPLEMENTARY REPORT
All-American Canal System
Boulder Canyon Project

Release No. 28 of the Operation and Maintenance Equipment and Proce-
dures bulletin, for April, May, and June 1959, presented the article

Cathodic Protection of Submerged Metalwork," by L. R. McGlocklin,
General Superintendent of the All-American Canal Section, and C, H.
Youngstrom, Senior Electrical Engineer, Planning and Power Depart-
ment, of the Imperial Irrigation District. The article described the
cathodic methods being used by the Imperial Irrigation District in
southeastern California to protect submerged metalwork in this large
irrigation project constructed by the Bureau of Reclamation, but now
operated by the district.

There has been great interest in the cathodic protection of metalwork
on our irrigation projects, as there has been elsewhere. In Irrigation
Operators' Workshop discussions held in the Chief Engineer's Office
in Denver in the late fall of 1962, we were fortunate in being brought
up-to-date on the performance of the cathodic protection systems
employed on the All-American Canal System by Mr. O. L. Fudge,
Manager of the Imperial Irrigation District's Water Department.

The protection of submerged
metal against corrosion or
electrolytic deterioration con-
tinues to be a major maintenance
item on the canal system and the
coating of metal surfaces to in-
sulate them from the water con-
tinues to be a widely used method
of accomplishing the needed pro-
tection. Cathodic protection,
however, has been successful
and over the last few years some
problems have been corrected.

Type of Anode

The previous article in Release
No. 28 mentioned the experimenta-
tion with various materials as
anodes. A high-silicon, cast
iron anode that was found to have
a very low rate of dissipation has
been adopted by the Imperial
Irrigation District and now is
being installed as replacement
becomes necessary. Photo-
graph No. 1 at left shows one of

Photo No. 1


Photo No. 6

Photo No. 7

2

1


Finishers are
easily able to keep
up with the place-
ment operations,
and it was reported
that approximately
800 to 1,000 linear
feet of lining are
being placed per
day at a cost esti-
mated between $2
and $2.50 per square
yard for the 2-inch-
thick lining.

Pigmented curing
compound is spray-
Photo No. 10 applied to the ex-
posed surfaces of
the concrete lining
following finishing
operations. Pro-
tection of the fresh
concrete from freez-
ing during winter
months is provided
by covering the lined
section with poly-
ethylene plastic film
supported at inter-
vals by timber planks
spanning the section
and anchored along
each side by sand-
bags. Heating is
provided by oil flare
Photo No. 11 pots spaced at 20- to

30-foot intervals
along the bottom of the lateral beneath the supported plastic cover.

A portion of the equipment used in the construction of the lining has
been obtained by the Arch-Hurley Conservancy District on a lease
purchase arrangement. The ditcher reportedly was purchased ata
cost of $27,000. The transit mixers were purchased secondhand from
transit-mix concrete companies who have but little use for the 4-cubic
yard capacity mixers, preferring larger equipment in their normal
operations. However, the smaller size mixers are ideally suited to
the work on the Tucumcari Project.

Approximately 27,000 square yards of 2-inch-thick unreinforced
portland cement concrete lining had been placed by the spring of

14


OPERATION AND MAINTENANCE
EQUIPMENT AND PROCEDURES
Release No, 45

July, August, and September 1963

INTRODUCTION

The Operation and Maintenance Equipment and Procedures bulletin
is published quarterly, for the benefit of irrigation project opera-
tion and maintenance people. Its principal purpose is to serve as

a medium of exchanging operation and maintenance information.

It is hoped that the labor-saving devices or less costly equipment
and procedures developed by the resourceful water users will be a
step toward commercial development of equipment for use on irriga-
tion projects in a continued effort to reduce costs and increase
operating efficiency.

This issue, Release No. 45, includes a supplementary report on
the use of cathodic protection to protect submerged metalwork,
page 1; an article on the rehabilitation of laterals on the Tucumcari
Project, New Mexico, by lining with slip-formed, portland cement
concrete, page 10; some helpful hints on mechanical maintenance;
and several ideas of the National Park Service that appear to have
adaptability to irrigation operation and maintenance work.

To assure proper recognition of those individuals whose suggestions
are published in the bulletins, the suggestion number as well as

the person's name is given. All Bureau offices are reminded to
notify their Suggestions Award Committee when a suggestion is
adopted.

Division of Irrigation Operations
Office of Chief Engineer
Denver, Colorado



Materials for the first pair of removable lights cost only $13.46,
including brackets, warning lights and the flasher circuit. The
person making up a set of lights should be careful to make the bar
aluminum, which sets into the car gutter, fit tightly to prevent
movement of the bracket. A sheet metal screw can be placed in
the bottom of the gutter to prevent any possibility of movement in
the bracket. The holddown spring should be firm enough to hold
tightly.

23

GPO 836 - 952



Cover Sheet. A reach of 2-inch-thick, slip-formed, portland
cement concrete lining placed by the Arch-Hurley Conservancy
District on the Tucumcari Project, New Mexico, as a part of
a lateral rehabilitation and betterment program.


TUCUMCARI PROJECT CONCRETE LATERAL LINING PROGRAM

The Tucumcari Irrigation Project, with 41,411 acres of irrigable
land, is located in Quay County in East Central New Mexico. The
project was constructed by the Bureau of Reclamation and is operated
by the Arch-Hurley Conservancy District. Mr. Sanford Caudill is
manager for the District. In March 1961, the District undertook re-
habilitation of project facilities, which will include drainage and lat-
eral lining where seepage problems on the project lands exist. The
lateral lining work is being accomplished in the off-irrigation season
and for this reason work will proceed for several years. The work
is presently being accomplished as a part of a Rehabilitation and
Betterment Program with the Bureau of Reclamation. The District,
however, plans to continue the work with their own funds until the
facilities are rehabili-
tated in all portions of
the project.

In the larger laterals,
10-mil thick polyvinyl
chloride plastic is being
used as a buried mem-
brane-type lining, follow-
ing construction practices
described in Release No.
40, page 15, of our ear-
lier Operation and Main-
tenance Equipment and
Procedures bulletin. How-
ever, it is project policy
Photo No. 1 to place 2-inch thick, slip-
formed, portland cement
concrete lining with a bot-
tom width of 2 feet in lat-
erals with a capacity of

60 cfs or less. A recently
completed section of this
slip-formed, concrete lin-
ing is shown on the cover
page.

The concrete lining op-
eration consists of first
filling the existing lat-
eral with compacted
Z earth. The lateral water
prism is then excavated
Photo No. 2 by a ditcher purchased
for the work by the Con-
servancy District. The commercially available ditcher is operated
to close excavation tolerances so far as line and grade are concerned

10


hopper in a satis-
factory manner to
provide a good top
edge for the lining,
and a concentric
electric vibrator

on the bottom and
back end of the hop-
per, which also re-
sults in a more con-
solidated and uni-
form bottom lining.
Weight has been
added to the rear

of the slip-form to
provide additional
stability and keep
the slip-form from floating.

Four electric motors are used
to power the screw conveyor,
the spading equipment, and the
electric vibrator on the bottom
of the hopper. Current for op-
eration of this equipment is
supplied from a portable motor
generator set, shown in Photo-
graph No. 8, mounted on the
rear of the slip-form. Addi-
tional independent generating
units operate the immersion-
type vibrators that are used

to move the fresh concrete and
keep it more uniformly dis-
tributed in the sli ‘orm hop-
per, although the screw con-
veyor does an excellent job in
this respect. A view of the
hopper filled with fresh con-
crete is shown in Photograph
No. 9.

The constructed lining appears
to have very good line and grade
and workmanship is very good.

Photo No. 9 A template used to cut dummy

joints in the fresh lining is

shown in Photograph No. 10, and one of the as yet unfilled joints is
shown in Photograph No. 11. These joints will be filled with mastic
after they have been cleaned.

13