400-D HYDRAULIC HAND GUN Assembly, Operation And .
400-D HYDRAULIC HAND GUNAssembly, Operation andMaintenance Manual
Flow ControlNordstrom ValvesContentsFlowserve Nordstrom Valve Sealants. 2Functions of Nordstrom Valve Sealants . 2400-D Hydraulic Hand Gun . 3Operation . 4Kits and Accessories . 5Parts List . 6Illustrations . 6Care and Maintenance . 8Troubleshooting Guide . 11Flowserve Nordstrom Valve SealantsAt Flowserve our primary goal is to serve lubricated valveusers with the highest quality sealant and sealant injectionequipment.We offer: A broad variety of valve sealants A flexible, service-oriented manufacturingfacility providing outstanding quality An experienced, dedicated staff ready toserve your needsThe success of Flowserve comes from customer service.Competent, experienced personnel handle your orders fromdevelopment, to order entry, to manufacturing, to shipping.We supply the most advanced formulations. Our highquality sealants range from -85 F to 700 F (-65 C to 371 C)and from air and water applications to the most aggressiveline fluids.Authorized Distributors . 12Functions of Flowserve Nordstrom Valve Sealants1. Drop-Tight Seal: To secure an absolutely tight seal, the film ofthe sealant works to form a seal between the sealing surfacesof the valve. The seal is formed by sealant transmitted througha system of passageways around the valve ports. With properselection of sealant for your particular service, a seal can beretained over a wide range oftemperatures and pressures.2. Lubrication: Prevents metal-to-metal contact of the valvesealing surfaces by filming over irregularities. No matter howfinely ground a metal surface may be, the metal is a series oftiny peaks and valleys. As one metal surface slides againstanother, friction is set up and adhesion, shearing or plowingmay result. A protective film of sealant between the bearingsurfaces prevents metal-to-metal rubbing.purpose, the sealant not only must have proper plasticity, butalso resistance to line fluids such as solvents and chemicals.Sealant forms a seal between the sealing surfaces of the valveeven under pressure.4. Plug Jacking: The fundamental operating principle of thetraditional lubricated plug valve design lies in the applicationof Pascal’s Law. The law states that a unit of pressure appliedto the liquid contained in a sealed vessel is transmittedto every part of the liquid with undiminished force, thusmultiplying the force many times, depending on the area of theinterior of the vessel. The sealant, under pressure developedby sealant injection, supplies the hydraulic means for liftingthe plug from its tapered seat when and if that force is neededto free the plug for easier operation.3. Renewable Seat: There is no need to disassemble alubricated valve or to remove it from service to replace mildlydamaged seats. Sealant, as a structural part of lubricatedvalves, provides a flexible and renewable seat, eliminatingthe necessity of force-fit contact to effect a seal. For this2400-D HYDRAULIC HAND GUN
Flow ControlNordstrom Valves400-D Hydraulic Hand GunThe Flowserve Nordstrom 400-D High-Pressure Hand Gunis rated at 10,000–11,000 psi (690–759 bar) and includes manyfeatures for meeting the exact demands of replacing sealant inlubricated valves.One of the most outstanding features of the 400-D Hand Gunis the large fluid capacity, which permits long periods of operationbetween recharging.In the 400-D Hand Gun, any air entrapment is eliminated byadding fluid when recharging, automatically purging the system ofair. The gun operates effectively in all positions.The floating piston in the gun is solid. There is no cap screwto cause fluid leakage and eventual operation failure.By using a special-formula hydraulic fluid in the pumpingmechanism, the gun pumps smoothly and with minimum effort.Its powerful hydraulic floating piston principle forces sealant outof the gun with ease, regardless of the sealant viscosity.The 400-D Hand Gun is equipped with a Giant Button HeadCoupler for connection to the button head sealant fitting of thevalve. This coupler has a design feature that locks it to the sealantfitting when the gun is under positive pressure. The couplercannot be connected to or separated from the fitting with the gununder pressure.400-D HYDRAULIC HAND GUNDue to the “built-in” safety features, the 400-D Hand Gunprovides maximum safety both to the user and the gun itself. Thehydraulic system of the gun is equipped with an internal reliefvalve to protect the operator if pumping continues after the gun isdepleted of sealant.The internal relief valve is tamperproof and is relativelyunaffected by temperature change and relieves approximately thesame pressure at temperatures between 0 F (-18 C) and 80 F(27 C), assuring maximum pump output throughout the variation.A pressure gauge indicates the point at which sufficientsealant pressure has been developed within the valve.In designing the 400-D Hand Gun, engineers concentrated ongreatly simplifying maintenance and repair procedures. In mostcases, the gun can be easily maintained and repaired by valveservice personnel, without requiring factory service.3
Flow ControlNordstrom ValvesOperationPreparing the400-D Hand Gun for UseThe 400-D Hand Gun is packaged with the Sealant Barrel Cap andhose assembly separate from the gun. To make the 400-D HandGun operational, all you need to do is load the gun with sealantand attach the cap and hose assembly. Refer to the NordstromSealant Brochure for information on the sealant required for yourspecific valve application.Loading the 400-DHand Gun with SealantThe 400-D Hand Gun is capable of pumping all viscositiesof valve sealants. The barrel is designed to accept a size “J” sealantstick (1.50" diameter x 8.75" length). Bulk grade sealants can beloaded into the gun manually or by using Nordstrom Gun Pak. Forthe Gun Pak, insert the heat-sealed end of the bag first.CAUTION: The 400-D Hand Gun is a hydraulic hand guncapable of developing high pressures. The followingoperating instructions should be read and followedclosely to assure the safe and proper use of theequipment.Note: Numbers in parentheses refer to gun parts, as illustrated onpages 6 and 7.1. “Crack” open the By-Pass Valve (12) by turning counterclockwise less than one full turn. It should not betightened against the By-Pass Stop (14). Backingout the By-Pass Valve too far will allow air to enterthe hydraulic system of the gun.2. Remove the Sealant Barrel Cap (26), complete withhose assembly, using the Handle with Grip (1). TheHandle is detachable and has a hole drilled near oneend. By unscrewing the Handle and placing the holeover the protruding pin on the Sealant Barrel Cap,the cap may be easily removed and replaced.3. Using the Handle as a push rod, return the FloatingPiston (41) to the bottom of the Sealant Barrel (24).4. Clean and replace the Handle.5. Close the By-Pass Valve. Do not jam the By-PassValve into the seat, as this may damage the sealingmember.6. Insert the J-Stick or Gun Pak (heat-sealed end first)into the Sealant Barrel.47. Operate the gun until the J-Stick or Gun Pakprotrudes approximately ¼" (6 mm) from the endof the Sealant Barrel.8. Replace the Sealant Barrel Cap and tighten snuglyusing the Handle.9. Before attaching the Giant Button Head Coupler(44) to the valve sealant fitting, operate the gun untilresistance is felt or the gun begins to build pressure(the hose will stiffen). Continue to pump until theinternal relief valve releases and note the pressure atwhich this occurs.10. Crack open the By-Pass Valve again to relieve pressureand then close. The 400-D Hand Gun is now ready forservicing lubricated valves.Lubricating Valveswith the 400-D Hand Gun1. Slide the Giant Button Head Coupler (44) overthe button head fitting on the valve to be injectedwith sealant.2. Tighten the By-Pass Valve (12).3. Begin sealant injection by pumping the Handle(1). It may take a number of strokes for the gun toprime itself and inject sealant into the valve.4. As the valve sealant system becomes full, the gunshould become harder to operate and a drop in pressureshould be visible on the gauge. When the valve is full ofsealant, open the By-Pass Valve and disengage the GiantButton Head Coupler. (Hydraulic pressure must be removedfrom the gun before the coupler can be removed.)Note: To retain most of the hydraulic pressure in the gun whenremoving from a valve, quickly crack open and close the By-PassValve. This will relieve enough hydraulic pressure to allow for easyremoval of the coupler but maintain enough pressure to keep fromrepriming the gun between valves.CAUTION: Do not continue pumping the gun after thesealant barrel has been emptied of sealant, as theFloating Piston Assembly may be damaged or the GunPak bag may be pumped into the hose.400-D HYDRAULIC HAND GUN
Flow ControlNordstrom ValvesKits and AccessoriesLinkage Assembly #60058Major Repair Kit tionButton Head Coupler Repair KitHydraulic Pump Cylinder withPiston 60041 & O-Ring 934005By-Pass ValveCheck Valve AssemblyHydraulic Fluid BagHydraulic Fluid (1 pint can)Nylon CupMinor Repair KitO-RingScrewMinor Repair Kit *O-RingO-RingO-RingO-RingO-RingConsists of 1 each: Spring, Washer, O-Ring, ValveCheck Valve Assembly 83905151930206ScrewWasherScreenSpringBall400-D Hoses by Length(¼" NPT Male and ½–27 Female)HoseLengthPartNumberHoseLengthPartNumber1 ft.1.5 ft.2 ft.6007647501475023 ft.4 ft.6 ft.19001094750347504400-D HYDRAULIC HAND PartDescriptionLinkWasherShoulder ScrewLock NutStop LinkFloating Piston 90001219000131900014PartDescriptionSealant Side NutNylon Cup*BodyO-RingOil Side NutBody Assembly #60065Button Head CouplerRepair Kit ic Pump Cylinder*ScrewWasherBy-Pass Stop ValveBy-Pass Valve*BodyScreenSpringBy-Pass Stop ScrewBallBy-Pass Valve O-RingPump Cylinder Top O-RingO-RingPump Cylinder Bottom O-RingInternal Relief ValveRepair ptionPiston Pulling ToolSpanner Wrench for Pump CylinderSpanner Wrench for Floating PistonFloating Piston GuideGun Assembly Wrench*Component of Major Repair Kit5
Flow ControlNordstrom ValvesNORDSTROM 400-D Hand Gun Parts52271397315 14353331461182918123456789101112131415166Part NameHandle with GripFulcrumLink (3)Screw, Check Valve (4)(6)Stop Link (3)Body, Hand Gun (4)Hydraulic Pump Cylinder with Piston (1)(4)Washer, Check Valve (4)(6)O-Ring, Pump Cylinder (top) (2)(4)O-Ring, Pump Cylinder (bottom) (2)(4)Screen, Check Valve (4)(6)By-Pass Valve (1)(4)O-Ring, By-Pass Valve (2)(4)By-Pass Stop (4)By-Pass Stop Screw (4)Internal Relief Valve 12121Ref.1819202122232425262729303132331016Part NameSpring, Check Valve (4)(6)Washer, Linkage (3)Shoulder Screw, Linkage (3)Sealing RingFluid Bag BarrelFluid Bag Barrel CapSealant BarrelO-Ring, Sealant Barrel (2)(4)Sealant Barrel CapLock Nut (3)Ball, Check Valve (4)(6)O-Ring, Pump Cylinder Piston (1)(2)O-Ring, Fluid Bag (1)(2)Hydraulic Fluid Bag (1)Nut, Sealant Side 60M1900010133111111311111400-D HYDRAULIC HAND GUN
Flow ControlNordstrom Valves13424263945OptionalSection B-B f or 400-D Hand Gun2540Ref.34353637383940414243444546363738Part NameCarry StrapNylon Cup (1)(5)Straight SwivelOne Foot HoseTeeNipple15,000 psi GaugeBody, Floating Piston (5)O-Ring, Floating Piston (2)(5)Nut, Oil Side (5)Giant Button Head CouplerShutoff & Relief Valve (optional)Screw, Fluid Bag (1)Gauge CoverHydraulic Fluid (1 pint can) (1)Z-Type Swivel (optional equipment)400-D HYDRAULIC HAND 70560090712519274361211111111111144(1) Component of Major Repair Kit(2) Component of Minor Repair Kit(3) Component of Linkage Assembly(4) Component of Body Assembly(5) Component of Floating Piston Assembly(6) Component of Check Valve Assembly7
Flow ControlNordstrom ValvesCare and MaintenanceSuggested CareThe following suggestions will ensure efficientand continued operation of the 400-D Hand Gun.1. Do not carry the gun by the Handle unlesssecured with the Carry Strap. Carrying the gunwith an unsecured handle can damage the Piston.2. Keep the Piston area of the gun free of debris.3. Do not unscrew the By-Pass Valve more than onecomplete turn. Doing so may allow air to enter thehydraulic system of the gun.4. Protect the Gauge from damage.MaintenanceIf the operating instructions are carefully followed and hydraulicfluid is added at regular intervals, the 400-D Hand gun will operateindefinitely without further maintenance. It is recommended amaintenance program be established where the number of hoursthe gun is used determines when maintenance is required.Note: Numbers in parentheses refer to parts as illustratedon pages 6 and 7 of this brochure.Recharging and Bleedingthe Hydraulic System of Air1. Open the By-Pass Valve (12) and remove the Handle (1).2. Remove the Sealant Barrel Cap (26) and standthe gun with the Sealant Barrel (24) up.3. With the Handle, press the Floating Piston (41)to the bottom of the Sealant Barrel. Make sure theFloating Piston bottoms out in the Sealant Barrel.4. Leave the Handle inside the Sealant Barrel and turnthe gun so the sealant barrel is pointing downwardand remove the Fluid Bag Barrel Cap (23).5. Slowly remove the Screw (46) and O-Ring (31) fromthe Fluid Bag (32).6. Allow the weight of the gun to rest against the Handleand slowly fill the Fluid Bag with NordstromHydraulic Fluid 71251. Allow the gun to stand 15 minutes topermit the air suspended in the fluid to escape. (It isrecommended to allow the gun to sit for 2 to 3 hours afterrecharging the hydraulic system with fluid to allow theFluid Bag to regain its original shape.)7. Replace the Screw and O-Ring, being careful not toentrap air.8. Remove the Handle and replace the Fluid Bag Barrel Cap.9. Reload the Gun with Sealant and replace the SealantBarrel Cap.8Replacing the Hydraulic Fluid Bag1. Remove the Handle (1), open the By-Pass Valve (12)and push the Floating Piston (41) to the bottom of theSealant Barrel (24). Clean the Handle and replace.2. Place the Fluid Bag Barrel (22) end of the gun in a vise.3. Place a suitable size container below the vise to catchhydraulic fluid.4. Using Gun Assembly Wrench 47521, remove the Body(6) and attached parts from the Fluid Bag Barrel.Hydraulic fluid will spill from the Fluid Bag.5. If the Floating Piston could not be returned to the bottom ofthe Sealant Barrel, return it now. See Step 1.6. Remove the damaged Fluid Bag (32) from the Fluid Bag Barreland clean the barrel.7. Remove the Sealing Ring (21).8. Place the Sealing Ring onto the new Fluid Bag, loosen theFluid Bag Screw (46) and tighten snug.9. Place the Fluid Bag into the Fluid Bag Barrel.10. Fill the Fluid Bag to within ¾" of the top with NordstromHydraulic Fluid 71251.CAUTION: Take care to keep foreign matterfrom entering the hydraulic fluid. Debris inthe hydraulic system can prevent the gunfrom operating properly.11. Replace the gun assembly removed in Step 4 and tightenby hand.12. Tighten the assembly to approximately 50 ft-lb using theGun Assembly Wrench.CAUTION: Overtightening the Fluid Bag Barrel to theBody may damage the Fluid Bag Assembly.13. After equipping the gun with a new Fluid Bag, recharge thegun with hydraulic fluid as described in this brochure.Sealant Barrel Replacement1. Open the By-Pass Valve (12) and push the FloatingPiston (41) to the bottom of the Sealant Barrel (24).2. Close the By-Pass Valve.3. Place the Sealant Barrel end of the gun in a vise and,with Gun Assembly Wrench 47521, remove the Body(6) and attached parts from the Sealant Barrel.4. Remove the Sealant Barrel from the vise and pushthe Floating Piston from the Sealant Barrel. Notethe position of the assembly when removing.400-D HYDRAULIC HAND GUN
Flow ControlNordstrom ValvesCare and Maintenance (cont.)5. Using Floating Piston Guide 47520, place the FloatingPiston into the non-knurled end of the new SealantBarrel. The Floating Piston should be flush with thebottom of the Sealant Barrel.CAUTION: Make sure the Sealant Barreland Floating Piston Assembly are free ofcontaminates prior to assembly.6. Replace the Sealant Barrel O-Ring (25).7. Place the Sealant Barrel onto the Body, withthe knurled end furthest away from the Body,and tighten hand-tight.8. Place the Sealant Barrel end of the gun into thevise and tighten the Body using Gun AssemblyWrench.9. After equipping the gun with a new Sealant Barrel,recharge the gun with hydraulic fluid as describedin this brochure.Pump Cylinder Replacement1. Remove the Handle (1), open the By-Pass Valve (12)and push the Floating Piston (41) to the bottom of theSealant Barrel (24). Clean the Handle and replace.2. With the gun in the horizontal position, Handle up,remove the Shoulder Screw (20) from the Pump Piston.3. Tip the linkage back.4. Unscrew the Hydraulic Pump Cylinder (7) withSpanner Wrench 47518. (The cylinder cavity willprobably fill with hydraulic fluid. Do not disturbthis condition.)5. Replace the O-Ring (10) in the bottom of the cylindercavity of the Body.6. Install O-Ring (9) on the new Hydraulic PumpCylinder. It is recommended that the cylinder bereplaced as assembly 60040.7. Install the new Hydraulic Pump Cylinder into theBody (6) and tighten with Spanner Wrench 47518.8. Reconnect the Linkage.9. After equipping the gun with a new Hydraulic PumpCylinder, recharge the gun with hydraulic fluid asdescribed in this brochure.Pump CylinderPiston O-Ring ReplacementRemove the defective Pump Cylinder Piston O-Ring (30) usinga sharp object. Pinch the O-Ring between the forefinger andthumb. Push the O-Ring into the top of the Hydraulic PumpCylinder (7) so that it partially enters the O-Ring groove. Use ablunt instrument to work the O-Ring completely into the groove.400-D HYDRAULIC HAND GUNCheck Valve RepairSymptoms of Check Valve failure are easily recognizable.When the Handle develops a spring-like action where,under pressure, the Handle will spring back each time itis pushed down, the Check Valve is not seatingproperly. This is usually indicative of a foreign particleon the valve seat.1. Open the By-Pass Valve (12) and push the FloatingPiston (41) to the bottom of the Sealant Barrel (24).2. Close the By-Pass Valve.3. Place the gun in a vise on a workbench and loosen theCheck Valve Screw (4).4. Remove the Check Valve Screw and Washer (8) andturn the gun Check Valve down so the Spring (18),Ball (29) and Screen (11) fall out.5. If it did not fall out, use a pointed instrument to removethe cylindrical Screen (11) from the Check Valve cavity.6. Thoroughly clean the Check Valve seat and cavity witha lint-free paper towel. The cleaning must be
400-D HYDRAULIC HAND GUN 5 Kits and Accessories Major Repair Kit #1900028 Part Part Qty. Number Description 1 47524 Button Head Coupler Repair Kit 1 60040 Hydraulic Pump Cylinder with Piston 60041 & O-Ring 934005 1 60048 By-Pass Valve 1 60059 Check Valve Assembly 1 70960M Hydraulic Fluid Bag 1 71251 Hydraulic Fluid (1 pint can)
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400-D Hydraulic Hand Gun – J-Stick or Gun Pak 400-A Hand Gun – J-Stick or K-Stick 400-B Bucket Pump – 30-pound bulk capacity For more detailed information on sealant injection equipment, refer to specific product brochures. Compact and efficient design. Air-operated sealant injection with 15,000 psi gauge.
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