Document Title: Revision No: 1

M800-Repair
Description: Repair Procedure for BAM800 Issue Date: 06/01
Nozzles

1. Clean:
Many nozzles that come back for repair will be covered in dirt and coal and have
no documentation stating damage, fault or reason for return of nozzle for repair.
Due to nozzles being returned in a filthy condition it is difficult to ascertain
problems with a visual inspection of the nozzle. Therefore it is important to
thoroughly clean the nozzle, paying particular attention to the front muzzle
region of the nozzle Body that connects onto the Fuel Receiver. Performing such
cleaning prior to testing will restrict the amount of contamination entering the
flow test circuit. A degreasing unit or parts wash down area is sufficient for
cleaning nozzles.

2. Identify Fault(s):
If possible, confirm the fault with the end-user – this will ensure the fault
identified by the customer will be rectified in addition to any other faults
identified.
Once nozzle has been cleaned it is then ready for fuel testing as per T004 . This
test will confirm the suspected fault, and identify any other problems to be
rectified during repair.

3 Dismantle:
Completely dismantle nozzle to sub-assemblies in reverse order of procedures
outlined in document M800 (Assembly Procedure for BAM800 Nozzles).
To remove Body from Housing, use tool T800-032 in conjunction with applying
a moderate amount of heat (preferably using a 0.5kg propane torch) around
thread area to crack Loctite seal.
Clean all parts in degreaser. Visually inspect all bores and sealing surfaces for
scratching or scoring. NB: The tolerances on both size and surface finish are
relatively fine to ensure the desired performance of the seals. For example,
the bores within the body and piston chamber used to house the AUS21A-020
U-Packing seals must measure Ø51.72±0.02mm and be of fine surface finish
(0.8 Ra or better). Contact Banlaw Pipeline should you require any further
information.

Of particular importance is the amount of wear within the front bore of the
Body. Excessive wear will create leakage from the front region of the nozzle
whilst refuelling. To confirm whether a replacement body is necessary,
thoroughly clean front bore of body and remove any protrusions of metal from
within same area – such material will give a false reading when the Body is
placed on the sizing jig. Place body onto Body Sizing Jig J21A-032-2 , and
discard any part which fits over Jig – indicating excessive wear within body.

M800 Repair – Revision 1 1

 NB: This Jig is suitable only for AUS21A-032 (mines) and AUS21A-032R (rail)
bodies.

Check all O'rings for nicks, scoring and other wear. Check all remaining parts for
damage, including excessive wear of clevis pins in lever arm and links. Any non-
conforming parts must be discarded and replaced with new parts.

Excessive wear or nicks and scores within the piston bore of the housing will
create an increased risk of leakage from the piston seal, premature seal failure,
and even a low shut-off pressure for the nozzle i.e. premature nozzle shut-off.
The photo shown in Figure 1 illustrates how the bore is inspected, with damage
to the bore surface circled in black marker pen.

Figure 1: Inspection of Piston bore in Housing

4. Assemble:
Once all parts have been checked and replaced if necessary, the nozzle can then
be assembled as per M800 using replacement parts as required.
If the sleeve o’rings require replacement use a pre-prepared Sleeve Assembly
as mentioned in M800. The older sleeve may only be reused if the old o’rings
are completely removed, the sleeve thoroughly cleaned, and new o’rings
installed as per M800 procedures.
It is important to follow all the assembly and test procedures thoroughly to
ensure a quality product will be returned to the customer. If the nozzle is
repaired properly it should have an equivalent service life to a new nozzle.

M800 Repair – Revision 1 2

5. Repair Information:
Once nozzle has been repaired, tested and conforms to all Test and Assembly
procedures, fill out nozzle repair sheet and hand into office for invoicing of
customer. Record date of repair, serial number, test results, parts used and file
under customer name for future reference. Include comments on any unusual or
excessive damage to parts indicating either harsh treatment or an inherent
weakness in the design of the part.

6. Authorised Distributors & Repair Agents:

All Authorised Distributors & Repair Agents are required to provide Banlaw
Pipeline with information on date of repair, serial number, test results and
parts used on a quarterly basis . This information is to help Banlaw ascertain
life of nozzle and also pin point any areas that may need future design
improvement. Such data will also allow Banlaw to monitor nozzle performance
on a customer specific basis, to ascertain whether professional consultancy could
be offered in order to improve refuelling practices.

7. Porosity:
The area on top of the Housing in the general area where the Handle is situated
can on occasion’s leak diesel caused by porosity in the casting. This is normally
detected during testing of the nozzle. The following procedure will rectify the
leak. This occurs on only about 2% of Housings .

a) Using a 10mm drill bit, drill about 10mm deep along the suspected path of
the pinhole leak.
b) Clean hole thoroughly with Acetone.
c) Fill hole with Devcon .
d) Once cured, remove excess with emery paper and retest nozzle as per leak
testing procedures in T004 .
e) If repair becomes difficult or unsatisfactory, replace Housing .

M800 Repair – Revision 1 3