Troubleshooting Guide - Flowserve 400-D Assembly, Operation And Maintenance Manual

These troubleshooting tips are provided as a means of assisting the consumer in recognizing operational difficulties sometimes
associated with the 400-D Hand Gun. Part numbers in parentheses denote illustration numbers as listed on pages 6 & 7 of this brochure.
WARNING: Never attempt to repair a 400-D Hand Gun without relieving the hydraulic pressure.
Problem: The gun will not pump.
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Cause 1: Air has entered the hydraulic system.
Solution 1: Bleed the hydraulic system. See page 8 of this
brochure. Tip!: With the Fluid Bag end of the Gun
positioned vertically in a vice, the Fluid Bag full of
oil, the Floating Piston pushed all the way into the
Sealant Barrel, and the By-Pass Valve open two
full turns, pump the handle 10 to 15 times. This
will ensure air entrapped in the hydraulic system
passages has been pumped into the Fluid Bag and
allowed to escape to the atmosphere.
Cause 2: The Piston is broken.
Solution 2: Replace the Pump Cylinder/Piston assembly.
See page 9 of this brochure.
Cause 3: The gun is void of sealant.
Solution 3: Refill the gun with sealant. See page 4 of this
brochure.
Cause 4: A Gun Pak bag has been forced into the hose by
attempting to inject sealant after the gun is void
of sealant.
Solution 4: Remove the Hose Assembly from the gun and
remove the bag from the Hose. You may attempt
this by flipping the hose and pumping out the bag.
Replace the Hose if the bag cannot be removed.
Cause 5: The Giant Button Head Coupler is damaged.
Solution 5: Replace the Giant Button Head Coupler or repair
the coupler using repair kit 47524.
Cause 6: Ambient temperature is low enough to cause the
sealant to become more viscous.
Solution 6: Place the gun and sealant in a warm place and only
expose them to cold temperature only during valve
injection.
Problem: The gun is difficult to pump.
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Cause 1: The supply of sealant is depleted.
Solution 1: Reload the gun with sealant. See page 4 of this
brochure.
Cause 2: The injection pressure of the sealant has not lifted
the plug from the seat of the valve.
Solution 2: Continue to inject sealant until the plug has been
lifted from the seat of the valve or until the Internal
Relief Valve relieves.
Problem: Hydraulic fluid leakage around the Body and
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Fluid Barrel threads.
Cause 1: Hydraulic Fluid is leaking past the Screw and
O-Ring in the end of the Hydraulic Fluid Bag.
Solution 1: Carefully tighten the Screw.
Cause 2: The Hydraulic Fluid Bag is damaged.
Solution 2: Replace the Hydraulic Fluid Bag.
See page 8 of this brochure.
400-D HYDRAULIC HAND GUN

Troubleshooting Guide

Problem: Floating Piston Assembly will not return to the
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bottom of the Sealant Barrel.
Cause 1: Air in hydraulic system.
Solution 1: Bleed the hydraulic system. See page 8 of this
brochure. See tip for problem "The gun will
not pump."
Cause 2: Excessive hydraulic fluid in gun.
Solution 2: Note: This procedure should be performed over
a basin to catch the excess hydraulic fluid.
Remove the Sealant Barrel Cap and insert the
Handle into Sealant Barrel against the Floating
Piston. Turn gun upside down and let the weight
of the gun rest on the Handle. Remove the
hydraulic Fluid Barrel Cap. Slowly remove the
Screw and O-Ring, located in the end of the
Hydraulic Fluid Bag, while lightly pressing the
gun down against the Handle. This will force out
excessive hydraulic fluid. Once the Piston is all the
way to the bottom of the Sealant Barrel, insert the
Screw and O-Ring into the Fluid Bag and replace
the Fluid Barrel Cap.
Problem: Hydraulic fluid leakage at the Sealant Barrel
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to Body threads.
Cause 1: The hydraulic fluid side Nylon Cup or O-Ring has
been damaged, allowing hydraulic fluid to enter the
sealant side of the Hydraulic Piston.
Solution 1: Clean and check the Nylon Cups for damage.
Replace parts if required. See page 10 of
this brochure.
Cause 2: The cylinder wall of the Sealant Barrel has been
scored, allowing hydraulic fluid to enter the sealant
side of the Hydraulic Piston.
Solution 2: Clean and check the Sealant Barrel for damage.
Replace the part if required. See page 8 of
this brochure.
Problem: The gun will not develop pressure when pumping.
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Cause 1: Air is present in the hydraulic system.
Solution 1: Bleed the hydraulic system. See page 8 of
this brochure.
Cause 2: The Check Valve Assembly is faulty.
Solution 2: Repair or replace the Check Valve Assembly.
See page 9 of this brochure.
Cause 3: The By-Pass Valve (12) is not sealing.
Solution 3: Tighten the By-Pass Valve while lightly tapping with
small hammer.
Cause 4: The Internal Relief Valve (16) has failed.
Solution 4: Replace the Internal Relief Valve.
Flow Control
Nordstrom Valves
11