Hydra-Stop LD4120 User manual

4”–12” Operang Instrucons — Revised April 2021
Hydra-Stopper LD4120 Line Stopping Machine

Hydra-Stopper™ LD4120 Line Stopping Machine | Operating Instructions | 2
© 2021 Hydra-Stop | All Rights Reserved. | Specifications subject to change without notice.
Secon 1 — General Safety Precauons
1.0.0 General Safety Precautions ....................................................... 3
Secon 2 — Tapping for 4”–8” HSF 250 Line Stop Fing
2.1.0 Mount and Pressure Test Fitting Body on Pipe......................... 5
2.2.0 Installing the Temporary Gate Valve ......................................... 5
2.3.0 Setting up the Hydra-Tapper ..................................................... 5
2.4.0 Installing the Hydra-Tapper ....................................................... 6
2.5.0 Performing the Line Tap ............................................................ 6
2.6.0 Removing the Hydra-Tapper...................................................... 7
Secon 3 — Tapping for the 10”–12” HSF 250 Line Stop
Fing
3.1.0 Mount and Pressure Test Fitting Body on Pipe......................... 8
3.2.0 Installing the Temporary Gate Valve ......................................... 8
3.3.0 Setting up the Hydra-Tapper ..................................................... 8
3.4.0 Installing the Hydra-Tapper ....................................................... 9
3.5.0 Performing the Line Tap .......................................................... 10
3.6.0 Removing the Hydra-Tapper.................................................... 10
Secon 4 — Line Stopping with the Hydra-Stopper
4.1.0 Setting up the Hydra-Stopper for Line Stopping..................... 12
4.2.0 Installing the Hydra-Stopper ................................................... 12
4.3.0 Performing the Line Stop ........................................................ 13
4.4.0 Removing the Hydra-Stopper.................................................. 13
4.5.0 Completing the Line Stop Procedure ...................................... 13
4.6.0 Maintenance and Storage ....................................................... 13
4.6.1 Temporary Valves .................................................................... 13
4.6.2 Hydra-Tapper........................................................................... 13
4.6.3 Hydra-Stopping Unit................................................................ 14
4.6.4 Changing the Stop Housing..................................................... 14
4.6.5 General Maintenance.............................................................. 14
4.6.6 Cutter Care .............................................................................. 14
Secon 5 — Appendices
Appendix A — Hydra-Stopper Parts ID Chart................................... 16
Appendix B1 — Hydra-Tapper Parts ID Chart Without OS&Y
Rising Stem....................................................................................... 17
Appendix B2 — Hydra-Tapper Parts ID Chart With OS&Y
Rising Stem....................................................................................... 18
Appendix C — 4”–8” HSF 250 Line Stop Fitting Body Install
Instructions....................................................................................... 19
Appendix D — 10”–12” HSF 250 Line Stop Fitting Body Install
Instructions....................................................................................... 21
Appendix E — 4”–8” Completion Plug Installation Instructions ...... 23
Appendix F — 10”–12” Completion Plug Installation Instructions .. 25
Appendix G — Line Stopping and the Importance of Equalization.. 27
Appendix H — Line Stop Trouble Shooting Guide ........................... 28
Table of Contents

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© 2021 Hydra-Stop | All Rights Reserved. | Specifications subject to change without notice.
SECTION 1.0.0 — General Safety Warnings
These instrucons depict the use of the most up-to-date Hydra-
Stop line stop ngs, tapping equipment, and accessories.
Please be certain you are following the instrucons for your
equipment.
General Safety Precauons — Read and Follow Instrucons
Carefully read and understand all safety messages in this
manual before using the equipment. The manuals provided
with the equalizaon pump must also be read for safety.
The maintenance procedures are to be followed to keep the
equipment in good working condion.
Personal Protecon
Hydra-Stop recommends that installers wear required personal
protecve equipment including but not limited to:
• Hard Hat
• Safety Shoes
• Safety Glasses
• Ear Protecon
• Gloves
Avoid wearing jewelry, such as rings, wristwatches, necklaces,
or bracelets. If working near trac, select ear protecon that
allows you to hear the trac for safety.
Keep Spectators Away from Installaon Area
Keep all spectators and other workers away from machines and
work area(s) while in operaon.
Clear Work Area
Clear the work area of all objects that might interfere with
the proper operaon of any tools. Avoid placing tools or other
objects where they can fall into the pit.
Do Not Work in an Unsupported Trench
Do not work in trench with unstable sides, which could cave in.
Specic requirements for shoring or sloping trench walls are
available from several sources including federal and state oces.
Be sure to contact suitable authories for these requirements
before working in the trench. A minimum 5’x 5’ excavaon is
recommended.
Locate the exisng pipe joints or ngs in the area and use the
appropriate restraint methods if necessary.
Check Laws and Regulaons
Know and obey all Federal, State, and local laws and regulaons
that apply to your work situaon.
Handling the Equipment
To avoid back injury, use proper liing techniques. Follow all
equipment instrucons when liing heavy loads.
Check Hardware and Equipment
Make sure that all air or hydraulic line couplings are ghtened
and secured to eliminate the chance of accidental uncoupling.
Use hose connecon retaining devices such as locking rings,
clips, pins, chains, or cables. Idenfy all equipment and tools
necessary for the size of HSF 250 you intend to install. Inspect
equipment to verify it is in good working condion and free of
wear and damage prior to use. Never start an operaon if the
equipment is not in proper working order. Contact Hydra-Stop if
equipment is not in working order.
Do Not Exceed Load Rang on Any Liing Equipment
This includes but is not limited to liing magnets, eye bolts and
straps. Liing magnets provided with Hydra-Stop equipment are
labeled with a load rang. 12” knife gate liing assists and 3/4”
eye bolts should ONLY be used for liing 12” and 8” temporary
gate valves respecvely.
WARNING: Failure to follow any of the above safety instrucons
or those that follow in this manual, could result in serious injury.
Any operaon involving work on pipe containing liquids or
gases under pressure is potenally hazardous. It is necessary,
therefore, that correct procedures be followed in the use and
maintenance of this equipment to maintain a safe working
environment.
No person should use this equipment who is not fully trained in
the procedures stated in this manual, and who is not fully aware
of the potenal hazards connected with work on pipe containing
liquids or gases under pressure.
The purchaser of this equipment is responsible for the manner
in which this equipment is used, maintained and the training,
competence and safety of the operators.
Should any diculty arise at any me in the use of this
equipment, please contact HYDRA-STOP at 708-389-5111
immediately.

Tapping Procedure for 4”–12” HSF Line Stop Installaon
Hydra-Stopper LD4120 Line Stopping Machine

Hydra-Stopper™ LD4120 Line Stopping Machine | Operating Instructions | 5
© 2021 Hydra-Stop | All Rights Reserved. | Specifications subject to change without notice.
Section 2 — Tapping for 4”–8” HSF 250 Line Stop
Fitting
2.1.0 Mount and Pressure Test Fing Body on Pipe
2.1.1) Select the proper HSF 250 for installaon. Idenfy the type
of pipe the HSF 250 will be installed on. Accurately measure the
outside diameter of the pipe.
2.1.2) Refer to Appendix C (page 19) to review the HSF 250 Line
Stop Fing Body Installaon Instrucons.
2.2.0 Installing the Temporary Gate Valve
2.2.1) Install the temporary gate valve. Use
the 8” temporary gate valve on 4”, 6”, and
8” HSF 250s. If using aluminum stopping
heads, posion the temporary gate valve at
the true 3, 6, 9, or 12 o’clock posion (see
Figure 1A). This will assist in the alignment
of an aluminum stopping head in the line
stopping procedure.
If using rubber stopping heads, you can
posion the temporary gate valve as shown
in Figure 1B.
NOTE: Temporary gate valves are single
direcon valves and must be posioned
top up. The 8” gate temporary valve must
be installed with the O-ring groove facing
up.
2.2.2) Bolt the temporary gate valve to
the top of the HSF 250 ange using the
bolts, nuts, and washers provided with the
installaon equipment. We recommend
using a cross-ghtening paern.
2.2.3) Install the O-ring in the groove of the
8” temporary gate valve (see Figure 1B).
2.2.4) Fully open the temporary gate valve.
NOTE: If you own an aluminum temporary
gate valve, fully close the temporary gate
valve and count the number of turns to
open. This is important to know in order to
check clearance issues later.
2.3.0 Seng up the Hydra-Tapper
2.3.1) Select proper size saw mandrel. Tapping of the 4”-8” HSF
250 requires the 27” long saw mandrel.
2.3.2) Select proper size shell cuer. Hydra-Stop shell cuers are
shipped painted black. If you repaint shell cuers in the future,
Hydra-Stop recommends painng them black.
• Installaon of 4” HSF 250 requires 3.8” cuer.
• Installaon of 6” HSF 250 requires 5.8” cuer.
• Installaon of 8” HSF 250 requires 7.9” cuer.
NOTE: Do not use red painted shell cuers to install the HSF
250. Hydra-Stop side tap shell cuers are shipped painted red.
Red painted side tap shell cuers are 1/2” undersized for side
tapping.
2.3.3) Select proper size pilot drill.
• Installaon of the 4” and the 6” HSF 250 ngs require the
1/2” X 6” long pilot drill.
• Installaon of the 8” HSF 250 ng requires the 1/2” X
7-1/4” length pilot drill.
NOTE: Tapping PVC or steel pipe will require a twist-style pilot
drill.
NOTE: Failure to use the proper sized or type of pilot drill will
result in a failed installaon.
2.3.4) Loosen and remove the Allen-head pilot drill retaining set
screw located on the side of the saw mandrel ange base.
2.3.5) Visually locate the tapered relief on the base of the pilot
drill. Noce the stop or ledge at the base of the taper (see Figure
2).
2.3.6) Mark the at of the taper with a visible marking agent (see
Figure 3).
2.3.7) Align the pilot drill at with the Allen-head set screw and
insert the pilot drill through the center of the saw mandrel stud
(see Figure 4).
2.3.8) Conrm you have completely inserted the pilot drill
and engaged the tapered at. Look into set screw hole for the
marking on the pilot drill. Adjust the pilot drill unl you can see
the marking (see Figure 5 on next page).
Figure 1A
Figure 3
Figure 2
Figure 1B
Figure 4

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2.3.9) Once aligned, insert and ghten the set screw. Test pull
the pilot drill to ensure the set screw is properly locked in place
against the pilot drill ledge. Check the coupon retaining clips so
they move freely (see Figure 6).
NOTE: Wear gloves when pulling on the pilot drill. Edges may be
sharp.
2.3.10) Loosen and back out the 2 Allen-head cap screws on the
ange of the saw mandrel unl ush with the face of the ange.
2.3.11) Thread the appropriate shell cuer all the way onto the
threaded stud of the saw mandrel’s anged end.
2.3.12) Back o to align the holes in the base of the shell cuer
with the Allen-head cap screws and thread them through the
holes. Tighten Allen-head cap screws.
2.3.13) Make sure the saw mandrel is clean and free of rust or
grime (steel wool can be used to clean and smooth the surface).
2.3.14) Lubricate the end of the saw mandrel with a dab of the
food-grade lubricant provided with the equipment to help it slide
freely through the packing nut assembly.
2.3.15) Slide the assembled shell cuer and saw mandrel into
the Hydra-Tapper unl the saw mandrel ange booms out in
the Hydra-Tapper.
2.3.17) Hand ghten the clamp lever on the packing nut
assembly to keep the assembled shell cuer and saw mandrel in
place.
NOTE: Do not use tools to ghten the clamp lever.
2.4.0 Installing the Hydra-Tapper
2.4.1) Using a strap or sling install the assembled Hydra-Tapper
onto the 8” temporary gate valve and align the bolt slots.
NOTE: Use extreme cauon not to damage the shell cuer or
pilot drill as the unit is raised and posioned on to the temporary
valve. Note the posion of the fully retracted cung assembly.
2.4.2) Install and cross ghten the bolts, nuts, and washers
to secure the assembly. Thread the 1/4” nipple and ball valve
into the tap housing and wrench ghten. Teon tape or thread
sealant can be used.
2.4.3) Hold and control the exposed saw mandrel, loosen the
packing nut assembly clamp lever, and slowly lower the saw
mandrel down unl the pilot drill is resng on the center top
of the pipe. Ensure the shell cuer spins freely in a clockwise
direcon.
2.4.4) Slide the stop collar over the saw mandrel.
2.4.5) Set the cung depth by measuring from the top of the
packing nut assembly to the lower side of the stop collar.
• 4” pipe = 3” cung depth
• 6” pipe = 4” cung depth
• 8” pipe = 5” cung depth
2.4.6) Tighten the stop collar to the correct
measurement (see Figure 7).
2.4.7) Install the drive unit by liing it above
the saw mandrel and slide it into the three
guide bars.
2.4.8) Lower the drive unit onto the
machined hex of the saw mandrel. Conrm
the drive unit is fully seated onto the
machined hex of the saw mandrel (see
Figure 8).
2.4.9) Install feed screw by
threading it through the top plate
of the Hydra-Tapper unl the
opening covers the spindle on the
drive unit.
NOTE: Do not apply downward force as it can damage the pilot
drill.
2.4.10) When the feed screw makes contact with the top of the
drive unit, back o one full turn.
2.4.11) If using a non-OS&Y tapping machine, assemble the
handle assembly and install over the ats at the top of the feed
screw and ghten the handles.
2.5.0 Performing the Line Tap
2.5.1) Ensure ball valve on the Hydra-Tapper P2 housing is open.
2.5.2) Connect the drive unit power source to the drive unit. The
air drive unit requires 90 CFM at 90 PSI. The hydraulic drive unit
Figure 7
(Measurement shown
for reference only)
Figure 5
Figure 6
Figure 8

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© 2021 Hydra-Stop | All Rights Reserved. | Specifications subject to change without notice.
requires 9 GPM at 1800 PSI.
2.5.3) Ensure the drive unit lever control is in the neutral
posion. Always run the power unit in the clockwise direcon.
NOTE: Avoid reversing as this will damage the carbide on the
pilot drill and carbide teeth on the shell cuer.
2.5.4) Engage the drive unit and conrm the saw mandrel is
rotang in the clockwise direcon. Slowly turn the feed screw
handle assembly in a clockwise direcon keeping slight, constant
pressure unl the tap is complete.
2.5.5) Close the ball valve on the P2 housing of the Hydra-Tapper
as water lls the housing and ows from the valve.
2.5.6) The tap is complete when the boom of the stop collar
makes contact with the top of the packing nut assembly.
NOTE: Do not overfeed the tap. Overfeeding the tap will cause
the shell cuer to jam.
2.5.7) Return the drive unit lever control to the neutral posion.
2.5.8) Loosen stop collar and connue to advance the feed
screw an addional two complete revoluons to ensure the
cut is complete. The shell cuer should spin freely. If it does,
disconnect the drive unit power source from the drive unit. If the
shell cuer does not spin freely, pull the drive unit lever control
down and conrm the saw mandrel is rotang in a clockwise
direcon. Slowly turn the handle assembly in a clockwise
direcon an addional two complete revoluons. Repeat steps
2.5.6 and 2.5.7
2.5.9) Slowly turn the handle assembly in a counterclockwise
direcon unl the stop collar has reached the starng
measurement.
• 4” pipe = 3” cung depth
• 6” pipe = 4” cung depth
• 8” pipe = 5” cung depth
2.5.10) Tighten the packing nut assembly clamp lever to lock the
saw mandrel in place. Remove feed screw. Remove drive unit.
2.5.11) Place a box end wrench over the hex
on the saw mandrel and use the wrench as
a lever brake to hold in place (see Figure 9).
2.5.12) Loosen the packing nut assembly
clamp lever and allow the pressure to
slowly raise the cuer assembly fully into
the tapping housing.
2.5.13) Conrm the shell cuer and saw
mandrel assembly is fully retracted and lock
the saw mandrel in place by ghtening the
packing nut assembly clamp lever.
2.5.14) Close the temporary gate valve. If
using an aluminum gate valve, make sure
you get the same number of turns to close as you counted in
step 2.2.4.
2.6.0 Removing the Hydra-Tapper
2.6.1) Relieve the pressure from the Hydra-Tapper by opening
the ball valve and discharging the pressure.
2.6.2) Connect the slings or straps to the Hydra-Tapper. Unbolt
and remove the Hydra-Tapper from the temporary gate valve.
Place the Hydra-Tapper in a dry and safe work area.
2.6.3) Remove stop collar.
2.6.4) Remove cuer and saw mandrel assembly.
2.6.5) Remove the coupon by loosening the Allen-head pilot drill
retaining set screw. Remove the pilot drill from the saw mandrel
stud.
2.6.6) Flip the pilot drill and insert it point end through the
hole in the coupon past the retaining clips and use it to pull the
coupon out of the cuer.
NOTE: Wear gloves when removing the coupon. Coupon edges
may be sharp.
2.6.7) Inspect the coupon for pipe thickness and condion.
2.6.8) Remove cuer from saw mandrel.
Figure 9

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© 2021 Hydra-Stop | All Rights Reserved. | Specifications subject to change without notice.
Section 3 —Tapping for 10”-12” HSF 250 Line Stop
Fitting
3.1.0 Mount and Pressure Test Valve Body on Pipe
3.1.1) Select the proper HSF 250 for installaon. Idenfy the type
of pipe the HSF 250 will be installed on. Accurately measure the
outside diameter of the pipe.
3.1.2) Refer to Appendix D (page 21) to review the HSF 250 Line
Stop Fing Body Installaon Instrucons.
3.2.0 Installing the Temporary Gate Valve
3.2.1) Install the temporary gate valve. Use
the 12” temporary gate valve for 10” and
12” HSF 250s. If using aluminum stopping
heads, posion the temporary gate valve at
the true 3, 6, 9, or 12 o’clock posion (see
Figure 10A). This will assist in the alignment
of an aluminum stopping head in the line
stopping procedure.
If using rubber stopping heads, you can
posion the temporary gate valve as shown
in Figure 10B.
NOTE: Temporary gate valves are single
direcon valves and must be posioned
top up. The 12” gate temporary valve must
be installed with the red bar facing up (see
Figure 10A or 10B).
3.2.2) Install the ange O-ring in the O-ring
channel on the HSF 250. Carefully lower
the 12” temporary gate valve into posion.
Ensure the temporary gate valve is centered
on the valve ange.
NOTE: Failure to center temporary
valve could cause mis-alignment
resulng in a failed installaon.
3.2.3) Bolt the temporary gate valve
to the top of the HSF 250 ange
using the nuts and washers provided
with the installaon equipment.
3.2.4) Install green ber gasket
(without holes) on the top side of
temporary gate valve (see Figure
10B).
3.2.5) Fully open the temporary
valve and re-check that temporary
valve is centered.
3.3.0 Seng up the Hydra-Tapper
3.3.1) Bolt Hydra-Tapper to the P-20 component using the
bolts and nuts included with Hydra-Tapper
equipment (see Figure 11).
3.3.2) Select proper size saw mandrel. Tapping
of 10” and 12” HSF 250s requires the 40” long
saw mandrel.
3.3.3) Select proper size shell cuer. Hydra-
Stop shell cuers are shipped painted black. If
you repaint shell cuers in the future, Hydra-
Stop recommends painng them black.
 Installaon of 10” HSF 250 requires a 9.8”
cuer.
 Installaon of 12” HSF 250 requires 11.8”
cuer.
NOTE: Do not use red painted shell cuers to install HSF 250.
Hydra-Stop side tap shell cuers are shipped painted red.
Red painted side tap shell cuers are 1/2” undersized for side
tapping.
3.3.4) Select proper size pilot drill. Installaon of 10” and 12”
HSF 250s requires the 3/4” X 10 5/16” long pilot drill.
NOTE: Tapping PVC or steel pipe will require a twist-style pilot
drill.
NOTE: Failure to use the proper sized or type of pilot drill will
result in a failed installaon.
3.3.5) Loosen and remove the Allen-head pilot drill retaining set
screw located on the side of the saw mandrel ange base.
3.3.6) Visually locate the tapered relief on the base of the pilot
drill. Noce the stop or ledge at the base of the taper (see Figure
12).
3.3.7) Mark the at of the taper with a visible marking agent (see
Figure 13).
3.3.8) Align the pilot drill at with the Allen-head set screw and
insert the pilot drill through the center of saw mandrel stud (see
Figure 14).
Figure 10A
Figure 13
Figure 12
Figure 11
Figure 10B
Figure 14

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3.3.9) Conrm you have completely inserted the pilot drill
and engaged the tapered at. Look into set screw hole for the
marking on the pilot bit. Adjust the pilot drill unl you can see
the marking (see Figure 15).
3.3.10) Once aligned, insert and ghten the set screw. Test pull
the pilot drill to ensure the set screw is properly locked in place
against the pilot drill ledge. Check the coupon retaining clips so
they move freely (see Figure 16).
NOTE: Wear gloves when pulling on the pilot bit. Edges may be
sharp.
3.3.11) Thread the appropriate shell cuer all the way onto the
threaded stud of the saw mandrel anged end.
3.3.12) Back o cuer to align
the holes in the base of the shell
cuer with the Allen-head cap
screw holes in the saw mandrel.
Thread screws from inside the
shell cuers and then into the
saw mandrel holes (see Figure
17).
3.3.13) Thread nylon lock nuts
onto Allen-head cap screws and
ghten (see Figure 18).
3.3.14) Make sure the saw
mandrel is clean and free of
rust or grime (steel wool can be
used to clean and smooth the
surface).
3.3.15) Lubricate the end of the
saw mandrel with a dab of the
food-grade lubricant provided
with the equipment to help it slide freely through the packing
nut assembly.
3.3.16) Slide the assembled shell cuer and saw mandrel into
the Hydra-Tapper unl the saw mandrel ange booms out in
the P-20 component.
3.3.17) Hand ghten the clamp lever on the packing nut
assembly to keep the assembled shell cuer and saw mandrel in
place.
NOTE: Do not use tools to ghten the clamp lever.
3.4.0 Installing the Hydra-Tapper
3.4.1) Using a strap or sling install the assembled Hydra-Tapper
on to the 12” temporary gate valve and align the bolt slots.
NOTE: Use extreme cauon not to damage the shell cuer or pi-
lot drill as the unit is raised and posioned on to the temporary
valve. Note the posion of the fully retracted cung assembly.
3.4.2) Cross ghten the bolts, nuts and washers to secure the
assembly. Thread the 1/4” nipple and ball valve into the tap
housing and wrench ghten. Teon tape or thread sealant can
be used.
3.4.3) Hold and control the exposed saw mandrel, loosen the
clamp lever, and slowly lower the saw mandrel unl the pilot
drill is resng on the top of the pipe. Ensure the shell cuer spins
freely in a clockwise direcon.
3.4.4) Slide the stop collar over the saw mandrel.
3.4.5) Set the cung depth by measuring from the top of the
packing nut assembly to the lower side of the stop collar.
3.4.6) Tighten the stop collar to the correct
measurement (see Figure 19).
• 10” pipe = 6” cung depth
• 12” pipe = 7” cung depth
3.4.7) Install the drive unit by liing it above
the saw mandrel and slide it into the three
guide bars.
3.4.8) Lower the drive unit onto the machined
hex of the saw mandrel. Conrm the drive unit
is fully seated onto the machined hex of the
saw mandrel (see Figure 20).
3.4.9) Install feed screw by threading it through
the top plate of the Hydra-Tapper
unl the opening covers the spin-
dle on the drive unit.
NOTE: Do not apply downward
force as it can damage the pilot
drill.
3.4.10) When the feed screw
makes contact with the top of the
drive unit, back o one full turn.
3.4.11) Assemble the handle
assembly and install over the ats
at the top of the feed screw and
ghten the handles.
Figure 15
Figure 16
Figure 17
Figure 18
Figure 19
(Measurement
shown for
reference only)
Figure 20

Hydra-Stopper™ LD4120 Line Stopping Machine | Operating Instructions | 10
© 2021 Hydra-Stop | All Rights Reserved. | Specifications subject to change without notice.
3.5.0 Performing the Line Tap
3.5.1) Ensure ball valves on the Hydra-Tapper P2 housing and the
P20 housing are open.
3.5.2) Connect the drive unit power source to the drive unit. The
air drive unit requires 90 CFM at 90 PSI. The hydraulic drive unit
requires 9 GPM at 1800 PSI.
3.5.3) Ensure the drive unit lever control is in the neutral
posion. Always run the power unit in the clockwise direcon.
NOTE: Avoid reversing as this will damage the carbide on the
pilot drill and carbide teeth on the shell cuer.
3.5.4) Engage the drive unit and conrm the saw mandrel is
rotang in the clockwise direcon. Slowly turn the handle
assembly in a clockwise direcon keeping slight, constant
pressure unl the tap is complete.
3.5.5) Close the ball valves on the P20 housing and the P2
housing of the Hydra-Tapper as water lls the housings and ows
from the valves.
3.5.6) The tap is complete when the boom of the stop collar
makes contact with the top of the packing nut assembly.
NOTE: Do not overfeed the tap. Overfeeding the tap will cause
the shell cuer to jam.
3.5.7) Return the drive unit lever control to the neutral posion.
3.5.8) Loosen the stop collar and connue to advance the feed
screw an addional two complete revoluons to ensure the
cut is complete. The shell cuer should spin freely. If it does,
disconnect the drive unit power source from the drive unit. If
the shell cuer does not spin freely, engage the drive unit and
conrm the saw mandrel is rotang in a clockwise direcon.
Slowly turn the handle assembly in a clockwise direcon an
addional two complete revoluons. Repeat steps 3.5.6 and
3.5.7.
3.5.9) Slowly turn the handle assembly in a counter-clockwise
direcon unl the stop collar has reached the starng
measurement.
• 10” pipe = 6” cung depth
• 12” pipe = 7” cung depth
3.5.10) Tighten the packing nut assembly clamp lever to lock the
saw mandrel in place. Remove feed screw. Remove drive unit.
3.5.11) Place a box end wrench over the hex
on the saw mandrel and use the wrench as a
lever brake to hold in place.
3.5.12) Loosen the packing nut assembly
clamp lever and allow the pressure to slowly
raise the cuer assembly fully into the
tapping housing (see Figure 21).
3.5.13) Conrm the shell cuer and saw
mandrel is fully retracted and lock the saw
mandrel in place by ghtening the packing
nut assembly clamp lever.
3.5.14) Close the temporary gate valve.
3.6.0 Removing the Hydra-Tapper
3.6.1) Relieve the pressure from the Hydra-Tapper by opening
the ball valve and discharging the pressure.
3.6.2) Connect the slings or straps to the Hydra-Tapper. Unbolt
and remove the Hydra-Tapper / P-20 assembly from the
temporary gate valve. Place the assembly in a dry and safe work
area.
3.6.3) Remove stop collar.
3.6.4) Remove cuer and saw mandrel assembly.
3.6.5) Remove the coupon by loosening the Allen-head pilot drill
retaining set screw. Remove the pilot drill from the saw mandrel
stud.
3.6.6) Flip the pilot drill and insert it point end through the
hole in the coupon past the retaining clips and use it to pull the
coupon out of the cuer.
NOTE: Wear gloves when removing the coupon. Coupon edges
may be sharp.
3.6.7) Inspect the coupon for pipe thickness and condion.
3.6.8) Remove cuer from saw mandrel.
Figure 21

Line Stopping with the Hydra-Stopper
Hydra-Stopper LD4120 Line Stopping Machine

Hydra-Stopper™ LD4120 Line Stopping Machine | Operating Instructions | 12
© 2021 Hydra-Stop | All Rights Reserved. | Specifications subject to change without notice.
Section 4 — Line Stopping with the Hydra-Stopper
NOTE: Rubber stopping heads are rated to 100 PSI. Aluminum
stopping heads are rated to 250 PSI. Make sure your tapping
machine is also rated to 250 PSI. Tapping machines with the gray
P-2 housing are only rated to 150 PSI. Contact Hydra-Stop if you
have any quesons.
4.1.0 Seng up the Hydra-Stopper for Line Stopping
4.1.1) Select the proper Stop Housing for your applicaon. Stop
housings come in 4”–8” and 10”–12” sizes.
4.1.2) Mount the pump and ram assembly to the stop housing
(see Secon 4.6.4 for changing the stop housing instrucons).
Use the eight 1/2” x 1” cap screws to mount the pump and ram
assembly to the stop housing. Ensure green ber gasket is placed
between stop housing and pump and ram assembly.
4.1.3) Aach a strap or sling to the Hydra-Stopper unit.
4.1.4) Raise the Hydra-Stopper so it can be pivoted to a
horizontal orientaon.
4.1.5) Lower the Hydra-Stopper so it is on the ground. Block as
needed to ensure the top of the pump is higher than the boom
of the pump and to prevent rolling (see Figure 22).
4.1.6) Move the Hydra-Stopper unit
actuator switch to the RIGHT — down
arrow (see Figure 23).
4.1.7) Engage the Hydra-Stopper handle
and pump. This acon will pump the
ram out of the Hydra-Stopper pump and
ram unit. Connue pumping unl the
ram clears the stop housing and you can
remove the shoulder bolts.
4.1.8) Ram is completely pumped out of the unit when
mechanical stop is reached.
4.1.9) For rubber stopping heads, aach the rubber stopping
head to the ram using the shoulder bolts. Skip to step 4.1.15.
4.1.10) For aluminum stopping heads, aach the aluminum
stopping head to the ram using the shoulder bolts.
4.1.11) Loosen the 4 set screws, this will allow the aluminum
stopping head to rotate.
4.1.12) Rotate the aluminum stopping
head so the rubber paddle at the boom
of the stopping head is parallel to the
ground and is level to the housing.
4.1.13) Tighten the 4 set screws to secure
the stopping head in place.
4.1.14) Make an alignment mark on the
stop housing between the two holes on
the ange directly right and le of the 12
o’clock posion. This mark will align with
the centerline of the pipe and will ensure
the rubber paddle is at a 90 degree angle to the pipe when the
Hydra-Stopper is placed on the temporary gate valve (see Figure
24).
4.1.15) Apply a liberal amount of food-grade grease to the
stopping head. Use Primo Lube (available from Hydra-Stop) or
food-grade grease. Never use petroleum-based grease.
Rubber stopping heads should be greased 360 degrees around
from top to boom. Do not grease the boom of the stopping
head. Aluminum stopping heads should be greased in the same
manner, apply grease to all the rubber components except the
boom of the paddle.
NOTE: FAILURE TO GREASE THE HYDRA-
STOP RUBBER WILL GREATLY REDUCE THE
PERFORMANCE OF YOUR STOP.
4.1.16) Depending on the model of your
Hydra-Stopper unit, open the bleeder
screw / petcock on the top of the ram
assembly.
4.1.17) Switch the actuator to the le (see
Figure 25).
4.1.18) Engage the Hydra-Stopper pump
handle and pump the ram all the way back into the housing. This
will bleed the air out of the system.
4.2.0 Installing the Hydra-Stopper
4.2.1) Using a strap or sling install the assembled Hydra-
Stopper on to the temporary gate valve and align the bolt slots.
No special alignment is required for rubber stopping heads.
Aluminum stopping heads must be 2-holed to the valve and the
main.
4.2.2) Locate eight 5/8” x 3” Hydra-Stop square-head nut, bolt,
and washer assemblies. Using the square headed nuts and bolts,
install and then ghten the bolts, nuts, and washers in a cross-
ghtening paern to secure the Hydra-Stopper to the temporary
gate valve.
Figure 23
Figure 25
Figure 22
Figure 24

Hydra-Stopper™ LD4120 Line Stopping Machine | Operating Instructions | 13
© 2021 Hydra-Stop | All Rights Reserved. | Specifications subject to change without notice.
4.3.0 Performing the Line Stop
4.3.1) Open the temporary gate valve.
4.3.2) Turn hydraulic actuator switch to the RIGHT (down arrow)
and pump the handle unl the pump automacally switches to
second stage, which indicates the stopping head has reached the
boom of the pipe. Connue pumping unl the gauge reaches
the desired pressure for that size of stop (see reference chart
below). Close the petcock on top of the reservoir and check the
quality of the stop before beginning the repairs.
NOTE: You cannot verify the quality of the stop by just making a
saw cut into the top of the pipe. It only takes a small amount of
water owing past the stop to keep the saw cut spraying water.
4.3.3) The chart below shows approximate pressure readings for
line stopping. Pressure readings apply to all types of pipe.
Pipe
Size
Gauge
Reading Rubber
Stopping Head
(approximate)
Recommended
Rubber Stop-
ping Head MAX
pressure
Gauge reading
Aluminum
Stopping Head
(approximate)
Recommen-
dated Alumi-
num Stopping
Head MAX
pressure
4” 1,600 PSI 2,100 PSI 800 PSI 1,300 PSI
6” 2,400 PSI 2,900 PSI 1,200 PSI 1,700 PSI
8” 3,200 PSI 3,700 PSI 1,600 PSI 2,100 PSI
10” 4,200 PSI 4,700 PSI 2,000 PSI 2,500 PSI
12” 5,000 PSI 5,500 PSI 2,400 PSI 2,900 PSI
NOTE: Do not exceed the recommended MAX pressure exerted
on the stopping head — damage to equipment or the pipe
could occur.
4.3.4) Verify that you have a workable shut down via a blow o
tap, branch connecon, or a hydrant before cung the pipe — a
2” blow o valve is recommended.
4.3.5) Perform the intended work in the isolated secon of
pipe. For safety, work on the pipe should be performed in a
separate excavaon from the line stop. Proper restraints or site
preparaon is recommended before the pipe is cut.
4.4.0 Removing the Hydra-Stopper
4.4.1) Slowly move the hydraulic actuator lever to the middle
posion (neutral) and wait 10–15 minutes to allow the stopping
head to regain its original shape and allow for the pipe to re-
pressurize and equalize. Line pressure must be equalized before
the stopping head can be removed. See Appendix G — Line
Stopping and the Importance of Equalization for additional
information.
4.4.2) Open the petcock on top of the hydraulic reservoir. Move
the control lever to the up posion. Begin pumping the handle
— it should be hard to pump. If the Hydra-Stopper switches into
second stage, move the control lever back to the neutral posion
and then back into the up posion.
The pump must stay in the rst stage to remove the stopping
head. If it does not, then you are not equalized and pumping in
the second stage will damage the equipment.
The handle will stop in mid-stroke when the stopping head is
fully retracted. To verify the stopping head is fully retracted, put
the control lever in the down posion and pump it 6 mes. If it
starts building pressure, then the stop is sll in the pipe and has
not fully equalized — repeat steps 4.4.1 through 4.4.2. If it does
not build pressure, return the control lever to the up posion
and pump the stop up those 6 mes.
NOTE: Retracng the stopping head in second stage will
damage the stopping head and it is possible that the stopping
head could be le in the pipe.
4.4.3) Close the temporary gate valve. Open the ball valve on
the line stop housing and the tapping machine, and bleed o the
pressure.
NOTE: When removing 12” temporary valve, place both sets of
nuts onto the top set of studs.
NOTE: Ensure the rubber or aluminum stopping head is
completely retracted in the Hydra-Stopper unit prior to closing
the temporary gate valve. If the temporary gate valve does not
fully close, the stopping head is insuciently retracted.
4.4.4) Aach a strap or sling to the Hydra-Stopper unit. Take up
slack in the strap or sling before removing the nuts and bolts
securing the Hydra-Stopper to the temporary gate valve.
4.4.5) Remove the nuts and bolts securing the Hydra-Stopper to
the temporary gate valve.
4.4.6) Remove the Hydra-Stop unit.
4.5.0 Compleng the Line Stop Procedure
4.5.1) For 4”–8” compleon instrucons, consult Appendix
E — 4”–8” HSF 250 Push and Pin Compleon Plug Installaon
Instrucons. For 10”–12” compleon instrucons, consult
Appendix F — 10”–12” HSF 250™ Push and Pin Compleon Plug
Installaon Instrucons.
4.6.0 Maintenance and Storage
The following secons provide informaon on the recommended
maintenance and storage of your Hydra-Stopper machine.
4.6.1 Temporary Valves
1. Close, wipe clean, and sanize.
2. When removing valve, place both sets of nuts onto the top set
of studs.
4.6.2 Hydra-Tapper
1. Remove saw mandrel from Hydra-Tapper housing.

Hydra-Stopper™ LD4120 Line Stopping Machine | Operating Instructions | 14
© 2021 Hydra-Stop | All Rights Reserved. | Specifications subject to change without notice.
2. Remove cuer and pilot drill from saw mandrel, remove set
screws from saw mandrel, then clean out and lubricate threads.
3. Remove feed screw and lubricate.
4. Check condion of cuers.
Note: Cuers can be re-pped. Contact Hydra-Stop for details.
5. Check condion on of the pilot drill. Replace coupon retenon
wire as needed (they must be straight and move freely to retain
the coupon).
4.6.3 Hydra-Stopper Machine
1. Remove stopping head from Hydra-Stop unit, wipe o excess
grease, and wash with warm soap and water.
3. Pump the ram all the way out and all the way in to bleed out
any air.
4. If the unit was used on a contaminated line, wash and rinse,
then swab with chlorine bleach.
5. With ram in up posion, remove the petcock at the top of the
hydraulic reservoir. The hydraulic oil level should be 1-1/2”–2”
below the top of the reservoir.
4.6.4 Changing the Stop Housing
1. Remove aached stopping head. Pump ram
all the way in.
2. Remove eight (8) 1/2” socket-head cap
screws from the base of the ram at the top of
the Hydra-Stop housing (see Figure 15).
3. Remove pump and ram from housing.
4. Place the green ber gasket on the stop
housing. Align the holes in the gasket with the
bolt hole paern on the stop housing.
5. Aach the ram to the stop housing using
the eight (8) 1/2” socket head cap screws (see
Figure 16).
6. Tighten to 75-foot pounds torque.
4.6.5 General Maintenance
1. Apply a thin coat of lubricant to all external parts.
2. Aluminum stopping heads retain water aer use, if the
3/4” Allen-head bolt (that holds the paddle in) is not removed
to allow the water to drain out, the water will freeze in cold
weather and could break the aluminum stopping head.
4.6.6 Cuer Care
Hydra-Stop carbide-pped cuers can be used on a wide range
of pipe materials, including: iron (cast and ducle), carbon steel,
asbestos cement, and PVC. Hydra-Stop cuers can easily be
re-sharpened. The high-quality carbide inserts are replaceable,
allowing for complete rebuilding of the cuer. Contact Hydra-
Stop for more informaon on the re-sharpening or rebuilding of
your cuer.
Please observe the following care and use instrucons to achieve
the longest life out of your Hydra-Stop cuer:
• Be sure to thread the cuer onto the saw mandrel and
back o unl the rst set of drive holes line up. Thread the
screws into the drive holes in the cuer and ghten. The
screws do not hold the cuer in place. The screws keep
the cuer from spinning and over ghtening on the saw
mandrel.
• Apply adequate, steady, and equal pressure when
advancing the drive unit through the tap. Allowing the
cuer points to contact the work without applying
adequate pressure or by applying too much pressure may
cause the cuer points to dull earlier than normal.
• Always wear safety glasses and use ear protecon while
making a tap. Keep ngers and hands away from the saw
mandrel and drive unit chuck while it is in operaon. Do
not wear loose clothing while operang the tap machine.
• Always clean and dry cuers aer use. Store cuers in a
humidity free environment to ensure against premature
rusng. Never lay cuer down on the carbide ps as this
can damage the teeth. When transporng, make sure
cuer is secure and stable.
Figure 15
Figure 16

Appendices
Hydra-Stopper LD4120 Line Stopping Machine

Hydra-Stopper™ LD4120 Line Stopping Machine | Operating Instructions | 16
© 2021 Hydra-Stop | All Rights Reserved. | Specifications subject to change without notice.
A Liing Ring
BPressure Gauge
CPetcock
D Operang Handle
EActuator Switch
FStop Housing
GStop Housing Ball Valve
Appendix A — Hydra-Stopper Parts Identification Chart

Hydra-Stopper™ LD4120 Line Stopping Machine | Operating Instructions | 17
© 2021 Hydra-Stop | All Rights Reserved. | Specifications subject to change without notice.
A Feed Screw
B Guide Bars (3)
C Standard Air or Hydraulic Drive
D Air Inlet Fing
E Saw Mandrel
F Adjustable Stop Collar
G Packing Nut & Mandrel
Locking Screw
H 1/4” Ball Valve
I Machined Tap Housing
J Cuer Mounng Flange
K Shell Cuer
L Pilot Drill
* Hydra-Stop has a full range of
tapping adapters: M.J., ANSI 150, NP16,
Korean, Australian. All inch
dimensions referred to are nominal pipe
diameters per industry standards.
Regardless of what type of Hydra-Stop
equipment you currently own, you can
easily convert to Hydra-Stopper™, Insta-
Valve 250, or Hydra-Tapper
equipment.
Appendix B1 — Hydra-Tapper Parts Identification Chart Without OS&Y Rising Stem

Hydra-Stopper™ LD4120 Line Stopping Machine | Operating Instructions | 18
© 2021 Hydra-Stop | All Rights Reserved. | Specifications subject to change without notice.
A OS&Y Rising Stem Assembly
B Guide Bars (3)
C Standard Air or Hydraulic Drive
D Hydraulic Quick Connectors
E Saw Mandrel
F Adjustable Stop Collar
G Packing Nut & Mandrel
Locking Screw
H 1/4” Ball Valve
I Machined Tap Housing
J Cuer Mounng Flange
K Shell Cuer
L Pilot Drill
* Hydra-Stop has a full range of
tapping adapters: M.J., ANSI 150, NP16,
Korean, Australian. All inch
dimensions referred to are nominal pipe
diameters per industry standards.
Regardless of what type of Hydra-Stop
equipment you currently own, you can
easily convert to Hydra-Stopper™, Insta-
Valve 250, or Hydra-Tapper equipment.
Appendix B2 — Hydra-Tapper Parts Identification Chart With OS&Y Rising Stem

Hydra-Stopper™ LD4120 Line Stopping Machine | Operating Instructions | 19
© 2021 Hydra-Stop | All Rights Reserved. | Specifications subject to change without notice.
IMPORTANT: Read installaon instrucons COMPLETELY before installing the HSF 250
line stop ng. Failure to follow installaon instrucons will void product warranty.
Follow local safety regulaons and use personal protecon equipment (PPE) as required
by naonal, state, and local regulaons.
INSTALLATION INSTRUCTION STEPS
C.1) Conrm bore of temporary gate valve is 8.5”. If the bore of your temporary gate
valves is smaller than 8.5” immediately call Hydra-Stop technical support (708-389-
5111).
C.2) Inspect the line stop ng to ensure no damage has occurred during shipment or
storage (see Figure 1). Locate and remove compleon plug and box containing stainless
steel mounng hardware. Store in a clean, safe locaon.
C.3) Measure pipe outside diameter where the line stop ng is being installed to
ensure the correct line stop ng is being used.
C.4) Thoroughly clean the pipe surface where the line stop ng will be installed and
inspect for aws (ex. gouges, protrusions, excessive corrosion, etc.). Irregular surfaces
should be avoided to assure maximum gasket sealing.
C.5) Lubricate top and boom of pipe and mat and branch gaskets with a soap/water
soluon. Ensure branch gasket is adequately lubricated. Do not use grease or pipe
lubricant.
C.6) Mount the top half of the line stop ng on the pipe in the posion required for
permanent installaon (see Figure 2). Use a level to ensure the ange is level. Do not
rotate the top half of the line stop ng aer it is posioned on the pipe.
C.7) Install the boom half of the line stop ng over the tapered ends of the mat
gasket ensuring they are at and smooth against the pipe surface. Visually inspect
gasket to ensure tapered ends are not folded or rolled under themselves. Install
stainless steel bolts, washers, and nuts (see Figure 3). Finger ghten, ensuring gaps
between top half and boom half of the line stop ng are the same front-to-back
and side-to-side — within 1/8” (see Figure 4). NOTE: It is acceptable to invert the
middle two bolts on each side of the 4” line stop ng to ulize a socket wrench for
installaon.
C.8) Using a torque wrench, ghten nuts in proper paern. Tightening paerns are
shown in Figure 5 and Figure 6. Repeat ghtening paern in no more than 25 . lb.
increments unl recommended torque is reached. NOTE: 8” ng has 10 total bolts
(see Figure 6 for 8” bolt torque sequence).
C.9) Wait 10 minutes to allow the gasket to fully seat then re-ghten bolts to
recommended torque three addional mes following the ghtening paern.
Recommended Torques:
CI / DI Pipe: 115 -lbs. PVC Pipe: 55 -lbs. AC Pipe: 75 -lbs.
C.10) Check inside of ng body outlet to ensure gasket is properly seated. Ensure
compleon plug set pins are ush with I.D. of the ange (see Figure 7).
Installaon instrucons and best pracces connued on next page.
Figure 1
Figure 2
Figure 3
Figure 5
Figure 4
Figure 6
Appendix C — 4”–8” HSF 250 Line Stop Fitting Installation Instructions

Hydra-Stopper™ LD4120 Line Stopping Machine | Operating Instructions | 20
© 2021 Hydra-Stop | All Rights Reserved. | Specifications subject to change without notice.
HYDRA-STOP FITTINGS — INSTALLATION BEST PRACTICES
• Keep nuts and bolts clean and free of debris.
• Adequately lubricate pipe and HSF 250 gaskets with soap/water soluon paying special aenon to AC pipe. Ensure branch
gasket is adequately lubricated. Do not use grease or pipe lubricant.
• Avoid rotang top half of HSF 250 ng once placed on pipe.
• Do not use a powered wrench to ghten nuts. You will gall the bolts and damage the ng.
• Block / support the pipe before installing the tapping machine.
• Ensure all pipe joints are restrained prior to proceeding to valve inseron operaon.
• Label ng body with a paint pen or permanent marker with the ghtening paern as a visual reminder of the ghtening
paern.
C.11) Fill ng body with water. Install test ange. Perform pressure test to ensure a
complete seal between the ng body and pipe (do not use a compressible medium
such as air). Pressure test ng with a Hydra-Stop Quick Test Plug kit or a standard test
ange. Contact Hydra-Stop for addional informaon.
Minimum Test Pressure: 1.5 mes the system working pressure
Maximum Test Pressure: 375 psi
C.12) Remove the test ange.
C.13) Following the ghtening paern, re-torque carriage bolts to recommended torque
before connuing.
C.14) Properly block (support) HSF 250 ng body and ensure pipe joints are properly
restrained. Proceed with line stopping operaon.
Call Hydra-Stop for technical support at 708.389.5111
and visit us on the web at www.hydra-stop.com.
Figure 7
Appendix C — 4”–8” HSF 250 Line Stop Fitting Installation Instructions
Completed installaon
of the HSF 250 line stop ng.
Pressure tesng with the
Hydra-Stop Quick Test Plug.