Document Title: Revision No: 1

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

1 Sub-Assemblies
1.1 Nozzle Housing Assembly

•
Squeeze a few drops of Loctite 577 into each ¼” BSW hole in Housing .
•
Attach Handle (AUS21A 022-1) to Housing (AUS21A 022) with cap head
screws (AUS21A 022-2) using a small drop of Loctite 277 on screw
threads
• Using a conservative amount of epoxy carefully affix Plaque A (AUS21A
022-4) to the PAT AUS 586085 side of nozzle and Plaque B (AUS21A
022-5) to the other side. Remove any excess adhesive.
• Place O’ring (AUS21A 026) into Housing.
NOTE: Ensure Bush (AUS21A 022-3) is in Housing . This is usually done at time of
manufacture.

MODEL SERIAL CODE

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Figure 1.1.1: Housing assembly

Figure 1.1.2: Plaque A (AUS21A 022-4) Figure 1.1.3: Plaque B (AUS21A 022-5)

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1.2 Sleeve Assembly

• Using wire brush (or fine emery paper) thoroughly remove zinc cadmium
plating from front O’ring grooves of Sleeve (AUS21A 024) and then clean
with Acetone .
• Spread Loctite 480 evenly around O’ring groove on face of sleeve. Place
Outer O’ring (AUS21A 024-3) in groove firmly, pat with cloth then press
firmly on bench top for about 10 seconds. Ensure O’ring is seated evenly in
groove. Remove all excess Loctite from o’ring and sleeve.
• Apply about 5 drops of Loctite 480 into inner O’ring groove and spread
evenly around groove. Place Inner O’ring (AUS21A 024-2) into groove and
push in firmly with T800-024-1 for about 10 seconds. Ensure O’ring is
seated evenly in groove. Remove all excess Loctite from o’ring and sleeve.
• Slide T800-024-2 over O’ring end of sleeve and liberally smear with Grease
then slide one U-Packing (AUS21A 020) into groove. Turn sleeve around
and repeat this procedure.
NOTE: This assembly must be prepared at least 24 hours prior to testing nozzle in
diesel to allow the Loctite 480 time to cure.

Figure 1.2: Sleeve assembly

1.3 Piston Assembly

•
Apply a small drop of Loctite 277 onto thread of Tube (AUS21A 021) at
the end of the Tube that has a 1/8” hole drilled 18mm from the end. Screw
Tube into Piston (AUS21A 019). When fully screwed up tight the length of
Tube protruding from the face of the Piston must be 149mm +0.0 / -0.2.
NOTE: Do not damage or score tube when tightening Piston .
• Slide T800-024-2 over backend of Piston and liberally smear with Grease
then slide U-Packing (AUS21A 020) into groove.

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 • Place one Link (AUS21A 017) on either side of milled section of Piston .
Insert Clevis Pin (AUS21A 016) through Ø6.5mm hole in Links and Piston .
Secure with Split Pin (AUS21A 015) .
• Place Lever Arm (AUS21A 018) between Links and insert Clevis Pin
through Ø6.5mm hole in Links and Lever Arm . Secure with Split Pin .

Figure 1.3: Piston assembly

1.4 Actuator Assembly

• Smear a liberal amount of epoxy inside Steel Bumper (AUS21A 044) and
slide onto Actuator (AUS21A 031-1) . Wipe off all excess epoxy with rag
and allow to cure for 24 hours.

Figure 1.4: Actuator assembly

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1.5 Body Assembly

• Insert Wiper Seal (AUS21A 037) into internal groove of Body (AUS21A
032).
• Insert Sleeve Assembly by O’ring end first into thread end of Body
• Place Sleeve Spring (AUS21A 023) on back of Sleeve .

Figure 1.5: Body assembly

1.6 End Cap Assembly

• Push fit one Oil Seal (AUS21A 009) into Ø28.6mm bore on either side of
End Cap (AUS21A 010).
• Insert Circlip (AUS21A 012) into appropriate groove in End Cap depending
on required shut off pressure of nozzle.

Figure 1.6.1: End cap assembly and Spring Settings (B800 series nozzles)
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Note the use of only 2 circlip grooves within the end-cap bore. The third “circlip”
position requires no circlip, as the Spring Retainer (AUS21A 013) is located by the
step at the rear of the end-cap bore.

Figure 1.6.2: End-Cap schematic

1.7 Handle Assembly

• Ensure each side of handle stem is smooth and free from burrs – remove
with file. This will ensure free action of trigger knobs on surface of stem.
• Press one Trigger Knob (AUS21A 003) onto Catch Pin (AUS21A 004 ).
• Slide Catch Spring (AUS21A 005) onto St/St Catch (AUS21A 006) and
insert into 12 mm hole of Handle (AUS21A 002)
• Tap Catch Pin & Trigger Knob through 5.2mm (height) slot in Handle and
Ø3/16” hole in St/St Catch. Press another Trigger Knob onto other end of
Catch Pin. Centralise catch pin and trigger knobs with respect to handle
stem.

NOTE: Ensure free movement of catch and confirm orientation of catch with respect to
broach angle is as shown in Figure 1.7. Placing the open slit of the catch pin along the
horizontal plane of the handle will eliminate friction between the edges of the slit and
the corresponding slot machined within the handle.

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 Figure 1.7: Handle assembly

Section 1 has outlined the various subassemblies to be prepared prior to assembly of

the nozzle. In particular, it is extremely important to have a number of Sleeve
Assemblies ready at all times, as it is imperative to allow the Loctite 480 a minimum
24 hour s to cure before any contact with diesel.

To minimise dust from accumulating on subassemblies, wipe off excess grease and
place a clean cloth over parts. If raw steel parts (unplated) are to be stored for an
extended period of time, apply a suitable rust prohibitive oil to exposed surfaces to
prevent corrosion. Any dust or other contamination must be removed from
subassemblies prior to final assembly in section 2.

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2 NOZZLE ASSEMBLY

Procedure:

1. Screw Housing Assembly by 2”NPT female thread onto J800-022-1 . Apply

Loctite 7471 Activator to threads and spread a thin line of Loctite 222
evenly around circumference of the thread of aluminium Body (AUS21A
032). Screw Body Assembly into Housing Assembly . Tighten using T800-
032. (NOTE: Use Loctite 277 for steel Body)
2. Ensure piston bore within Housing is clean and free from any damage.
Liberally smear Grease around inside of T800-022-1 . Place T800-022-1
into Ø62mm bore of housing and insert Piston Assembly .
3. Screw Retainer (AUS21A 025) onto Tube and securely tighten using T800-
025. Take care to ensure no cross-threading between threads.
4. Move piston assembly fore and aft to confirm free and easy movement of the
assembly. Force provided by sleeve spring should rapidly return assembly to
the fully forward position. Awkward, “jerky”, or difficult movement could be
an indication of improper seal installation or poor surface finish in seal bores.
NB: poor surface finish within a bore may be rectified by carefully honing or
polishing the bore surface with 1200 grit wet & dry emery paper (or
equivalent). Care must be taken to ensure the bore diameter is not
increased beyond Ø51.72±0.02mm by excessive polishing. Such error
will cause seal leakage and affect the shut-off performance of the nozzle.
Remove nozzle from J800-022-1 .
5. Air pressure test both the front and back of nozzle assembly as per Air Test
Procedure T001 . Rectify any leaks.
6. Screw Housing Assembly by 2”NPT female thread back onto J800-022-1 .
7. Liberally smear Grease around the eight Ø6.5mm holes on circumference of
Body . Place one Ball lock (AUS21A 038) into each hole of Body (8 in total).
8. Insert Dust Seal (AUS21A 028) into groove in Actuator. Place Actuator
Spring (AUS21A 030) into largest diameter of Actuator . Slide Actuator
Assembly over Body and secure by placing Stock Ring (AUS21A 039) into
groove at front of body. NOTE : to ensure seal is not damaged by actuator
spring, apply grease to dust seal and twist actuator whilst placing over body.
9. Place Back Spring firmly into groove of Piston and place Spring Retainer
(AUS21A 013) within end-cap in required position. NOTE: Ensure required
shut-off pressure will be obtained by confirming circlip in end-cap is
positioned correctly and proper spring is being used as stated in Figures
1.6.1 and 1.6.2.

a) AUS21A 029 Back (piston) Spring caters for Light (L), Medium-Light
(ML), and Medium (M) settings. The shut-off pressure of the Light and
Medium settings are equal to those achieved of the AUS21A 014-3
(light) and AUS21A 014 (medium) springs used in the AUS/BMS21
series nozzles. The new ML setting will cater for those applications
where a L setting causes premature nozzle shut-off, whilst the M
setting is considered too high.

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 b) AUS21A 027 Back (piston) Spring caters for Medium-Heavy (MH)
and Heavy (H) settings. The shut-off pressure of the Heavy setting is
equivalent to that achieved by the AUS21A 014-2 (heavy) spring used
in the AUS/BMS 21 series nozzles. The new MH setting will cater for
those applications where a M setting causes premature nozzle shut-off,
whilst the H setting is considered too high.

10. Place End Cap Assembly over Spring . Ensure Spring seats correctly
within Spring Retainer and Spring Retainer seats squarely onto Circlip .
NOTE: whilst installing end-cap assembly, align lever arm squarely between
brass bushes inside rear of end-cap. This will greatly assist step 12.
11. Secure End Cap to Housing with Cap Head Screws (AUS21A 011) using
a small drop of Loctite 277 on each screw.
12. Insert T800-001 through φ 18.3mm holes in End Cap and 3/8” square
hole in Lever Arm .
13. Apply Grease to each Oil Seal (AUS21A 009) within End Cap . Push one
Brass Bush (AUS21A 008) into Oil Seal on each side of End Cap and align
with T800-001 . Insert remaining Brass Bush (AUS21A 008) into opposing
Oil Seal (AUS21A 009) and align also with T800-001.
14. Place Handle Assembly on End Cap and tap Square Shaft (AUS21A
001) through Handle, Brass Bushes and Lever Arm . Ensure correct
orientation of Handle as per Figure 1.7. Remove T800-001 .
15. Apply a small amount of Loctite 277 onto each Cap head Screw
(AUS21A 035). Insert Washers (AUS21A 034) & Cap head Screws into
either side of handle pivot and tighten handle onto square shaft.

NOTE: Steps 9 to 15 may be performed with the nozzle mounted on J800-022-2 ,

although the natural tendency for the Lever Arm to locate between each Brass Bush
whilst mounted on J800-022-1 will assist in step 11.

Figure 2.1: End-Cap schematic

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 16. With the nozzle in the “ON” position put a straight edge e.g. 6” ruler over
the top of the Bumper and whilst holding actuator fully forward, measure
with Vernier Calipers to the top of Retainer and record measurement. Turn
nozzle to the “OFF” position and repeat. Subtract the first measurement from
the second measurement. A difference of 22.0mm ±0.5mm is required for
the nozzle to operate correctly, and allow the nozzle to be readily connected
to the receiver whilst under pump pressure. This is called the displacement of
the central nozzle assembly. This must be checked on every nozzle
assembled . If this measurement is not achieved, check the following:

IMPORTANT NOTE For New (unused) End Caps: Due to cumulative machining and
assembly tolerances, the correct position of the catch detent on the end cap may vary
for each nozzle. To compensate for this, extra material has been cast onto the end cap
on the underside of the catch detent. Unwanted material may be removed by filing as
per Figure 2.2. Care must be taken to correctly locate the handle catch and thus
ensure the required 22.0mm ±0.5mm displacement of the central nozzle
assembly.

a) A lower value may indicate the operating handle catch is failing to

hold the central assembly in the proper OFF position, indicating
incorrect handle installation – refer section 1.7 - or excessive wear in
the links, lever arm, handle catch or the catch detent on the end cap.
Parts must be examined and replaced if necessary.
b) overall length of the nozzle tube, retainer and piston assembly –
nozzle must be dismantled. This measurement must be as stated in
section 1.3.
c) a higher value , although not jeopardising the operation of the nozzle,
may restrict a nozzles ability to fully shut-off and thus should be
corrected. Such a value may indicate either an incorrectly positioned
catch or catch detent on the end cap. See also point b).

Figure 2.2: Locating Catch Detent

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 17. Fuel test Nozzle as per T004 .
18. Attach Nozzle Plug (AUS21A-P) to Nozzle.
19. Attach Stickers onto Nozzle as per Figure 2.3 below. NOTE: Additional
stickers are prohibited , unless prior authorisation from Banlaw Pipeline Pty
Ltd has been granted.

Figure 2.3: Location of stickers on nozzle

NOTE: the “ON – OFF” Sticker may be placed on the
Actuator below (behind) the “Warning” sticker, as
attaching the sticker to the cast surface is often difficult

20. Stamp Serial Code and Model numbers in spaces provided on Plaque A
using 4mm punch set . Stamp the Spring Setting of the nozzle as shown in
Figure 2.4 below. Record this information in BAM800 Nozzle Book. NOTE:
Additional markings are prohibited, unless prior authorisation has been
granted by Banlaw Pipeline Pty Ltd.

MODEL Number / Code: BAM800 – Standard 800LPM Mines Diesel Nozzle

BAR800 – Standard 800LPM Rail Diesel Nozzle
BAH800 – Standard Hydraulic (oil) Nozzle

SERIAL CODE: 4 character alpha code e.g. ABCD (example only)

- unique code assigned for each nozzle
- code used to track history of nozzle

Spring Setting Codes: L – Light (AUS21A-029 spring, position 3)

ML – Medium/Light (AUS21A-029 spring, position 2)
M – Medium (AUS21A-029 spring, position 1)
MH – Medium/Heavy (AUS21A-027 spring, position 3)
H – Heavy (AUS21A-027 spring, position 2)

- see Figure 1.6.1 for c’clip positions -

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 MODEL SERIAL CODE

MODEL SERIAL CODE

Figure 2.4: Location of Spring Setting Stamping on nozzle

21. Wrap Nozzle in plastic packaging bag and place into store. Complete Job
Card details and submit for processing of nozzle into stock

Attachments:

• Appendix A: - drawings of tools and jigs required

- BAM800 Assembly Drawing

• Appendix B: - shut-off pressure graphs for BAM800 nozzle

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