Flowserve 400-D User Manual
400-D HYDRAULIC HAND GUN
Assembly, Operation and
Maintenance Manual
Contents
Flowserve Nordstrom Valve Sealants ............................................ 2
Flow Control
Nordstrom Valves
Functions of Nordstrom Valve Sealants ........................................ 2
400-D Hydraulic Hand Gun ........................................................... 3
Operation ...................................................................................... 4
Kits and Accessories .................................................................... 5
Parts List ...................................................................................... 6
Illustrations ................................................................................... 6
Care and Maintenance .................................................................. 8
Troubleshooting Guide ................................................................ 11
Authorized Distributors ............................................................... 12
Flowserve Nordstrom Valve Sealants
At Flowserve our primary goal is to serve lubricated valve
users with the highest quality sealant and sealant injection
equipment.
We offer:
• A broad variety of valve sealants
• A flexible, service-oriented manufacturing
facility providing outstanding quality
• An experienced, dedicated staff ready to
serve your needs
The success of Flowserve comes from customer service.
Competent, experienced personnel handle your orders from
development, 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 aggressive
line fluids.
Functions of Flowserve Nordstrom Valve Sealants
1. Drop-Tight Seal: To secure an absolutely tight seal, the film of
the sealant works to form a seal between the sealing surfaces
of the valve. The seal is formed by sealant transmitted through
a system of passageways around the valve ports. With proper
selection of sealant for your particular service, a seal can be
retained over a wide range of
temperatures and pressures.
2. Lubrication: Prevents metal-to-metal contact of the valve
sealing surfaces by filming over irregularities. No matter how
finely ground a metal surface may be, the metal is a series of
tiny peaks and valleys. As one metal surface slides against
another, friction is set up and adhesion, shearing or plowing
may result. A protective film of sealant between the bearing
surfaces prevents metal-to-metal rubbing.
3. Renewable Seat: There is no need to disassemble a
lubricated valve or to remove it from service to replace mildly
damaged seats. Sealant, as a structural part of lubricated
valves, provides a flexible and renewable seat, eliminating
the necessity of force-fit contact to effect a seal. For this
purpose, the sealant not only must have proper plasticity, but
also resistance to line fluids such as solvents and chemicals.
Sealant forms a seal between the sealing surfaces of the valve
even under pressure.
4. Plug Jacking: The fundamental operating principle of the
traditional lubricated plug valve design lies in the application
of Pascal’s Law. The law states that a unit of pressure applied
to the liquid contained in a sealed vessel is transmitted
to every part of the liquid with undiminished force, thus
multiplying the force many times, depending on the area of the
interior of the vessel. The sealant, under pressure developed
by sealant injection, supplies the hydraulic means for lifting
the plug from its tapered seat when and if that force is needed
to free the plug for easier operation.
2
400-D HYDRAULIC HAND GUN
Flow Control
Nordstrom Valves
400-D Hydraulic Hand Gun
The Flowserve Nordstrom 400-D High-Pressure Hand Gun
is rated at 10,000–11,000 psi (690–759 bar) and includes many
features for meeting the exact demands of replacing sealant in
lubricated valves.
One of the most outstanding features of the 400-D Hand Gun
is the large fluid capacity, which permits long periods of operation
between recharging.
In the 400-D Hand Gun, any air entrapment is eliminated by
adding fluid when recharging, automatically purging the system of
air. The gun operates effectively in all positions.
The floating piston in the gun is solid. There is no cap screw
to cause fluid leakage and eventual operation failure.
By using a special-formula hydraulic fluid in the pumping
mechanism, the gun pumps smoothly and with minimum effort.
Its powerful hydraulic floating piston principle forces sealant out
of the gun with ease, regardless of the sealant viscosity.
The 400-D Hand Gun is equipped with a Giant Button Head
Coupler for connection to the button head sealant fitting of the
valve. This coupler has a design feature that locks it to the sealant
fitting when the gun is under positive pressure. The coupler
cannot be connected to or separated from the fitting with the gun
under pressure.
Due to the “built-in” safety features, the 400-D Hand Gun
provides maximum safety both to the user and the gun itself. The
hydraulic system of the gun is equipped with an internal relief
valve to protect the operator if pumping continues after the gun is
depleted of sealant.
The internal relief valve is tamperproof and is relatively
unaffected by temperature change and relieves approximately the
same 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 sufficient
sealant pressure has been developed within the valve.
In designing the 400-D Hand Gun, engineers concentrated on
greatly simplifying maintenance and repair procedures. In most
cases, the gun can be easily maintained and repaired by valve
service personnel, without requiring factory service.
400-D HYDRAULIC HAND GUN
3
Operation
Flow Control
Nordstrom Valves
Preparing the
400-D Hand Gun for Use
The 400-D Hand Gun is packaged with the Sealant Barrel Cap and
hose assembly separate from the gun. To make the 400-D Hand
Gun operational, all you need to do is load the gun with sealant
and attach the cap and hose assembly. Refer to the
Sealant Brochure
specific valve application.
for information on the sealant required for your
Nordstrom
Loading the 400-D
Hand Gun with Sealant
The 400-D Hand Gun is capable of pumping all viscosities
of valve sealants. The barrel is designed to accept a size “J” sealant
stick (1.50" diameter x 8.75" length). Bulk grade sealants can be
loaded into the gun manually or by using Nordstrom Gun Pak. For
the Gun Pak, insert the heat-sealed end of the bag first.
CAUTION: The 400-D Hand Gun is a hydraulic hand gun
capable of developing high pressures. The following
operating instructions should be read and followed
closely to assure the safe and proper use of the
equipment.
Note: Numbers in parentheses refer to gun parts, as illustrated on
pages 6 and 7.
1. “Crack” open the By-Pass Valve (12) by turning counter clockwise less than one full turn. It should not be
tightened against the By-Pass Stop (14). Backing
out the By-Pass Valve too far will allow air to enter
the hydraulic system of the gun.
2. Remove the Sealant Barrel Cap (26), complete with
hose assembly, using the Handle with Grip (1). The
Handle is detachable and has a hole drilled near one
end. By unscrewing the Handle and placing the hole
over 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 Floating
Piston (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-Pass
Valve into the seat, as this may damage the sealing
member.
6. Insert the J-Stick or Gun Pak (heat-sealed end first)
into the Sealant Barrel.
7. Operate the gun until the J-Stick or Gun Pak
protrudes approximately ¼" (6 mm) from the end
of the Sealant Barrel.
8. Replace the Sealant Barrel Cap and tighten snugly
using the Handle.
9. Before attaching the Giant Button Head Coupler
(44) to the valve sealant fitting, operate the gun until
resistance is felt or the gun begins to build pressure
(the hose will stiffen). Continue to pump until the
internal relief valve releases and note the pressure at
which this occurs.
10. Crack open the By-Pass Valve again to relieve pressure
and then close. The 400-D Hand Gun is now ready for
servicing lubricated valves.
Lubricating Valves
with the 400-D Hand Gun
1. Slide the Giant Button Head Coupler (44) over
the button head fitting on the valve to be injected
with 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 to
prime itself and inject sealant into the valve.
4. As the valve sealant system becomes full, the gun
should become harder to operate and a drop in pressure
should be visible on the gauge. When the valve is full of
sealant, open the By-Pass Valve and disengage the Giant
Button Head Coupler. (Hydraulic pressure must be removed
from the gun before the coupler can be removed.)
Note: To retain most of the hydraulic pressure in the gun when
removing from a valve, quickly crack open and close the By-Pass
Valve. This will relieve enough hydraulic pressure to allow for easy
removal of the coupler but maintain enough pressure to keep from
repriming the gun between valves.
CAUTION: Do not continue pumping the gun after the
sealant barrel has been emptied of sealant, as the
Floating Piston Assembly may be damaged or the Gun
Pak bag may be pumped into the hose.
4
400-D HYDRAULIC HAND GUN
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