Document title: BPM800 Repair Revision No: 1

Description: Repair Procedure for BPM800 Issue Date: 02/06

Nozzles

1.0 Repair Procedure

1.1 Clean
To prevent contamination entering the nozzle assembly area, and to assist in
identifying the reason(s) for the nozzle being removed from service, it is
important to thoroughly clean the nozzle prior to disassembly. In particular, the
front muzzle region of the nozzle should be flushed clean to remove grit and
other contaminants. A degreasing or parts wash-down unit may assist in this.

1.2 Investigate
Nozzles are returned for service/repair often with no paperwork explaining the
fault(s). If possible, the customer should be contacted in an effort to identify the
reasons so that they may be specifically addressed.

A nozzle should be assessed to both correct faults and prevent potential

problems. All suspect parts should be replaced to ensure the nozzle is returned
to service in an “as new” operating condition.

Visually inspect the nozzle for structural faults, i.e. fractures, impact damage, and
general wear and tear.

If possible, the nozzle should be flow tested as per document T004 to identify
leaks from either the front of rear of the nozzle prior to disassembly. Fuel leaks
are amongst the more prevalent faults, largely due to damaged seals or
contamination build-up.

1.3 Disassembly
Section 2 of this document outlines the various sub-assemblies which make up a
complete nozzle. The nozzle should be dismantled by systematically removing
each sub-assembly using the specified tools and jigs.

Once the nozzle is cleaned and has undergone an initial fault assessment, it
should be completely dismantled to allow a thorough inspection of each part and
to remove all contamination. This is especially important between moving parts
and sealing surfaces.

Loctite thread-locking compounds are “cracked” by applying localised heat to the

thread area using a small propane torch. Threads must be thoroughly cleaned of
all contamination prior to reassembly.

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BPM800 Repair – Rev 1 © 2006 BANLAW PTY LTD
Caution: Banlaw uses Viton seals in its products. Viton is a hazardous material
when heated. Be sure to identify location of seals within nozzle assembly prior to
applying heat to threads and consult the attached MSDS for further information.

1.4 Fault Identification and Remedy

The 2 most common reasons a nozzle is returned for repair are:
• Structural damage as a result of a drive-away, general wear and tear, or
abuse.
• Fuel leaks from worn seals, or excessive contamination around the seals.

1.4.1 Fuel Leaks – Front End

Fuel leaks whilst refuelling will generally occur due to either a faulty sleeve face
seal or sleeve U-seals. Although the Wiper Seal (AUS21A###) will assist in
sealing between the receiver and nozzle, the primary seal between the nozzle
and receiver is the outer lip of the face seal.

Fuel leaks whilst the nozzle is disconnected from the receiver are generally
caused either from a poor seal between the inner annulus of the sleeve face seal
and the retainer, or faulty sleeve U-seals.

Contamination around the sleeve U-seals will often damage the bore of the Body.
Minor imperfections to the bore can be removed using fine emery paper (P1200).
The bore must measure Ø51.72±0.02mm and have a smooth and consistent
finish. The bore sizing can be quickly confirmed using the Body Sizing Jig J21A-
032-2, with any Body passing over the Jig being faulty.

The face seal used on the Sleeve is non-serviceable, with the Sleeve supplied
with the face seal already intact.

1.4.2 Fuel Leaks – Rear End

The piston U-seal (BP800-019-1) is the solitary seal at the rear end of the nozzle.
Fuel leaks from the rear of the nozzle, e.g. from the bleed hole on the underside
of the End-Cap, indicate a poor seal between the U-seal and piston bore.

As with the bore of the Body, the piston bore of the Housing will suffer scoring
and damage from contamination build-up. Dirty fuel will deposit contamination at
the forward side of the Piston, whilst contamination at the rear side of the Piston
will enter via the bleed hole on the End-Cap or between the interface of the
Housing and End-Cap. The piston bore must measure Ø44.80±0.02mm and
have a smooth and consistent finish. Minor surface imperfections may be
removed using fine emery paper (P1200), however the Housing must be
replaced if the damage is irreparable.

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BPM800 Repair – Rev 1 © 2006 BANLAW PTY LTD
1.4.3 Other Key Problem Areas
In addition to sections 1.4.1 and 1.4.2, a number of other key areas should be
carefully considered during each nozzle service.
a) difficulty in connecting the nozzle onto the receiver with the supply line
pressurized, i.e. by pump pressure. This can occur if the nozzle Retainer
and Sleeve are permitted to sit too far forward with the T-Handle locked
OFF. This problem primarily occurs due to a combination of high wear
between clevis pins and mating parts in the piston sub-assembly – evident
with excessive free-play in the action of the T-Handle - and wear from the
cast catch detent on the underside of the End-Cap. These problems
decrease the required 22.0±0.5mm linear displacement of the central
nozzle assembly between ON and OFF positions, by failing to return the
Retainer and Sleeve fully back in the OFF position. Both these problems
should be thoroughly assessed and any faulty parts replaced.
b) Poor action of the nozzle actuator will increase the effort required when
connecting the nozzle and receiver, and may prevent proper engagement
of the ball locks. Damage sustained to the front end of the nozzle Body
may impinge upon the Bumper or Actuator, thus restricting the free
movement of the Actuator sub-assembly. Such damage must be either
repaired, or the parts replaced. Attention should also be paid to excessive
wear or damage to the inner surface of the Actuator onto which the ball
locks contact. Such wear may jeopardize the effectiveness of the ball
locks.
c) Aside from structural damage to the Actuator, Body and Housing, further
damage sustained from a drive-away may include such things as a bent
Tube. The Tube can also sustain such damage as a result of an object
being jammed between the Retainer and Sleeve, such as in the event of
fuel pilferage. A damaged Tube may decrease the Safe Working Pressure
of the nozzle, and increase the effort required to displace the central
nozzle assembly when turning the nozzle between ON and OFF positions.
This increase in effort will increase the shut-off pressure of the nozzle,
creating the risk of tank overpressurisation.
d) Wear between mating parts of the nozzle operating mechanism, i.e. the
piston and T-handle sub-assemblies, will affect the proper operation of the
nozzle – as discussed in point (a). Any parts exhibiting excessive wear or
other damage must be replaced.
e) The bore at the front of the Body can be exposed to relatively high wear,
particularly if the nozzle plug (or anchor) and receiver dust caps are not
used, or the receiver is not wiped clean prior to connecting the nozzle.
Excessive wear will increase the clearance with the mating receiver and
thus increase the amount of “rocking” (angular movement) possible
between the nozzle and receiver. This will create additional strain on the
effectiveness of the seal between the sleeve face seal and the face of the
receiver leading to the risk of leakage. The front bore of the Body may be
checked on the Body Sizing Jig, with any Body freely passing over the jig
deemed unsatisfactory.

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BPM800 Repair – Rev 1 © 2006 BANLAW PTY LTD
2.0 Sub-Assemblies
A number of sub-assemblies are available to assist in the repair process. Three
(3) sub-assemblies are available:
1. Housing sub-assembly
2. T-Handle sub-assembly
3. Actuator sub-assembly

2.1 Housing Sub-Assembly

This sub-assembly consists of the following individual parts:
• Housing (BP800-022) – 1 of (##).
• Housing Bush (BP800-022-3) – 1 of (##).
• Plaque - serial (BP800-022-4) – 1 of.
• Plaque - web (BP800-022-5) – 1 of.
(##): Not available separately.

MODEL SERIAL CODE

Hydrocarbon Management Specialists
AU & US PATENTS PENDING & GRANTED www.banlaw.com

Plaque A (BP800-022-4) Plaque B (BP800-022-5)

Figure 2.1 – Housing Assembly

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BPM800 Repair – Rev 1 © 2006 BANLAW PTY LTD
2.2 T-Handle Sub-Assembly
This sub-assembly consists of the following individual parts (not available
separately):
• T-Handle (BP800-002) – 1 of.
• Catch (BP800-006) – 1 of.
• T-Handle Bung (BP800-007) – 2 of.
• Trigger Knob (AUS21A003) – 2 of.
• Roll Pin (AUS21A004) – 1 of.
• Catch Spring (AUS21A005) – 1 of.
CATCH PIN HANDLE BUNG
TRIGGER KNOB
BP800-004 BP800-007
AUS21A-003
CATCH SPRING
HANDLE AUS21A-005
BP800-002

ENSURE CLEARANCE
(EACH SIDE)

OBSERVE RELATIONSHIP
BETWEEN BROACH ANGLE
AND INSTALLED CATCH

5°

Figure 2.2 – T-Handle Sub-Assembly

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BPM800 Repair – Rev 1 © 2006 BANLAW PTY LTD
2.3 Actuator Sub-Assembly
The standard spec Actuator (BP800-031-1) and Bumper (AUS21A044) sub-
assembly is assigned the part number BP800-031.

The JN125 spec Actuator (BPJN800-031-1) and Bumper (AUS21JN044) sub-

assembly is assigned the part number BPJN800-031.
ACTUATOR
STANDARD: BP800-031-1
JN125: BPJN800-031-1
BUMPER
STANDARD: AUS21A-044
JN125: AUS21JN-044

Figure 1.4 - Actuator Assembly

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BPM800 Repair – Rev 1 © 2006 BANLAW PTY LTD
3.0 Quality Assurance (QA)
As an accredited QA company, Banlaw prides itself on maintaining consistently
high standards in all product and service related issues within the global market.
With respect to nozzle repairs, any nozzle returned for service must be
assessed, repaired and tested in accordance with Banlaw guidelines to ensure
the nozzle is returned to service in an “as-new” condition and eligible for warranty
under the Banlaw Terms & Conditions of Product Warranty.

Please do not hesitate to contact Banlaw or your nearest authorised Banlaw

Distributor should you have any queries regarding this document or any quality
Banlaw product.

BANLAW PTY LTD

Ph: 61 2 49724777
Fax: 61 2 49714910
Email: sales@banlaw.com.au
www.banlaw.com.au

Distributor & Business Manager – Systems Engineering Manager

Development Manager Development & Support (Mechanical)
Steve Clayton John Gregory Adam Peattie
0409 045017 0408 492408 0412 704838
steve@banlaw.com.au john@banlaw.com.au adam@banlaw.com.au

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BPM800 Repair – Rev 1 © 2006 BANLAW PTY LTD