BPM800 > BPM800 - rev 1

CONFIDENTIAL INFORMATION Hydrocarbon Management Specialists BPM800 Rev 1 © 2006 BANLAW PTY LTD

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Document title: BPM800 Revision No: 1

Description: Assembly Procedure for BPM800 Nozzles

Issue Date: 02/06

1.0 Sub-Assemblies 1.1 Nozzle Housing Assembly

• Confirm the BP800-022-3 Brass Bush is installed within the central bore of the Housing.

• Attach Handle (BP800-036) to Housing (BP800-022) with cap head screws (BP800-036-1) with Loctite 277 applied to the threads. Tighten securely.

• Using a conservative amount of epoxy carefully affix Plaque A (BP800-022-4) to the right side of the Housing and Plaque B (BP800-022-5) to the left side. Remove excess adhesive with acetone.

• Place O’ring (AUS21A026) into the front of the Housing.

FRONT

AUS21A-026O'RING

AU & US PATENTS PENDING & GRANTED

SERIAL CODEMODELHydrocarbon Management Specialistswww.banlaw.com

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

Figure 1.1 – Housing Assembly


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1.2 Sleeve Assembly The Sleeve is supplied with the Face Seal intact – this is moulded and vulcanized onto the aluminium Sleeve during manufacture. This seal is a non-serviceable item, and must be replaced in conjunction with the sleeve.

• Please observe correct orientation of U-seals as illustrated in Figure 1.2. Take care to avoid any damage to the seals during their installation and subsequent storage prior to use.

• Using tool T800-024-2 over the front of Sleeve, lightly smear grease over the taper of the tool and slide a U-seal (AUS22-020) into the front groove. Turn sleeve around and repeat this procedure to install the second U-seal (AUS22-020) into the rear groove.

SLEEVEBP800-024

U-SEALSAUS22-020

FACE SEAL

FRONT

Figure 1.2 - Sleeve Assembly


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1.3 Piston Assembly

• Apply a small drop of Loctite 277 onto thread of Tube (AUS21A021) at the end of the Tube that has a 1/8” hole drilled 18mm from the end. Screw Tube into Piston (BP800-019). When fully screwed up tight the length of Tube protruding from the face of the Piston must be 149mm+0.0 / -0.2.

NOTE: Take care not to bend, damage or score tube when tightening Piston. Remove any rough finish or marks with fine emery paper (P1200).

• Observing its correct orientation (Fig. 1.3), carefully stretch the U-seal (BP800-019-1) over the front end – small end – of the Piston and into the seal groove. Ensure seal sits properly within groove. A little grease applied to the seal may assist its installation.

NOTE: Take care to avoid any damage to the U-seal during its installation or subsequent storage prior to use.

• Place one Link (AUS21A017) on either side of milled section of Piston. Insert Clevis Pin (AUS21A016) through Ø6.5mm hole in Links and Piston. Secure with Split Pin (AUS21A015).

• Place Lever Arm (AUS21A018) between Links and insert Clevis Pin through Ø6.5mm hole in Links and Lever Arm. Secure with Split Pin.

NOTE: if necessary, trim excess from legs of each split pin.

59.5

PISTON U-SEALBP800-019-1

PISTONBP800-019

LINKS (2 OF)AUS21A 017

FRONT

4.0

148.8149.0

TUBEAUS21A 021

SPLIT PIN AUS21A 015(1 EACH END)

CLEVIS PIN AUS21A 016(1 EACH END)

25.0

LEVER ARMAUS21A 018

Figure 1.3 - Piston Assembly


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1.4 Actuator 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.

• Smear a sufficient coverage of epoxy inside Bumper and slide onto Actuator. Wipe off all excess epoxy with rag and acetone and allow to cure for 24 hours.

NOTE: rotating the Bumper around the Actuator approx. half a turn during assembly assists in the even distribution of epoxy between mating surfaces.

• Install Dust Seal (AUS21A028) into Actuator as shown in Figure 1.4. Ensure seal sits squarely and fully within the groove.

BUMPERSTANDARD: AUS21A-044JN125: AUS21JN-044

DUST SEALAUS21A-028

ACTUATORSTANDARD: BP800-031-1

JN125: BPJN800-031-1

Figure 1.4 - Actuator Assembly


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1.5 Body Assembly

Using fine emery paper (P1200), create a smooth and even finish within the tail bore of the Body prior to installation of the Sleeve Assembly. This removes any fine imperfections and the often inherent roughness created by the anodized surface of the bore. Take care not to remove the anodized surface, only any minor surface imperfections.

• Insert Wiper Seal (AUS21A037) into internal groove of Body

(AUS21A032).

NOTE: the Wiper Seal is more readily installed into the Body from its tail (threaded) end. Take care not to damage the seal during installation.

• Lightly smear the tail bore of the Body with grease and insert the Sleeve

Assembly by seal end first into tail end of Body. • Place Sleeve Spring (BP800-023) onto back of Sleeve.

BALL LOCKS

WIPER SEALAUS21A-037

SLEEVE SPRINGBP800-023

BODYMINING: AUS21A032RAIL: AUS21A032RJN125: AUS21JN032HYDRAULIC: AUS21A032B

SLEEVE ASSEMBLY

Figure 1.5 - Body Assembly


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1.6 End Cap Assembly Correct installation of the Oil Seals is essential to avoid an unsatisfactory level of friction when subsequently operating the T-Handle after assembly of the nozzle.

• Confirm the small Ø1/16” bleed hole has been machined through the underside of the End-Cap (BP800-010). Using compressed air, thoroughly clean the interior of the End-Cap being sure to remove all machining waste and any residue casting material.

• Push fit one Oil Seal (AUS21A009) into each Ø28.6mm counter-bore on either side of the End Cap. Ensure each seal sits fully and squarely within its seat.

• Insert Circlip (AUS21A012) into appropriate groove in End Cap depending on the required shut off pressure of nozzle, i.e. L, ML, M, MH or H.

NOTE: Position 3 requires no Circlip.

SPRING SETTING TABLE

PRESSURES RELATE TO STATIC BACK-PRESSUREINITIATING NOZZLE SHUT-OFF @ 350LPM

BANLAW 800 SERIES NOZZLE

MED. HEAVY

OBSERVE ORIENTATIONOF INSTALLED SEAL

1 65-75kPa

CIR

CLI

P P

OS

ITIO

N

LIGHT MED.

3

2LIGHT

25-35kPa

45-55kPa

SPRING

MEDIUM

BP800-029

29.352

23.85

35.70

APPLICABLE

80-90kPa

90-100kPaHEAVY

NOT

BP800-0271

3

A

OIL SEALAUS21A009

A

SECTION A-A

Figure 1.6 – End-Cap Assembly and Spring Settings


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1.7 T-Handle Assembly

Ensure each side of T-Handle stem (especially surrounding catch pin slot) 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 (AUS21A003) into Catch Pin (AUS21A-004). • Slide Catch Spring (AUS21A-005) onto St/St Catch (BP800-006) and

insert into Ø12 mm bore of T-Handle (BP800-002) – ensure correct orientation of St/St Catch with respect to the broach angle (Fig. 1.7).

• Tap Catch Pin & Trigger Knob through 5.2mm (height) slot in T-Handle and Ø3/16” hole in St/St Catch. Press another Trigger Knob onto other end of Catch Pin.

NOTE: Centralise Trigger Knobs with respect to T-Handle stem and make certain inside of each Trigger Knob does not contact corresponding face of T-Handle stem to ensure free action of spring loaded catch.

5°

BETWEEN BROACH ANGLEAND INSTALLED CATCH

OBSERVE RELATIONSHIP

ENSURE CLEARANCE(EACH SIDE)

CATCH SPRINGAUS21A-005HANDLE

BP800-002

TRIGGER KNOBAUS21A-003

CATCH PINBP800-004

HANDLE BUNGBP800-007

Figure 1.7 - T-Handle Assembly


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Comments Section 1 has outlined the various subassemblies to be prepared prior to assembly of the nozzle. In particular, it is essential to allow any Loctite or other such product the correct curing period prior to further use – please refer to the manufacturers recommendations. To minimise dust from accumulating on subassemblies, wipe off excess grease and place a clean cloth over stored parts. If raw steel parts (unplated) are to be stored for an extended period of time, apply 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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2.0 Nozzle Assembly 2.1 Assembly of Housing and Body Sub-Assemblies

• Using compressed air and a clean rag, thoroughly remove all dust and contamination from the Housing and Body sub-assemblies - in particular mating threads. Use Acetone to remove oil/grease if necessary.

• Apply Loctite 7471 Activator to the tail thread of the Body and the mating thread at the front of the Housing. Allow around 15mins drying time.

• Mount Housing Assembly by 2”NPT female thread onto jig J800-022-1, and confirm the O’ring (AUS21A026) is properly seated in the front end of the Housing (Fig. 1.1).

• Apply a thin and even coverage of Loctite 222 Thread-locker to the thread at the tail of the Body.

• Whilst ensuring proper seating of the Sleeve Spring into the Housing, screw the Body sub-assembly into the front of the Housing. Tighten firmly using tool T800-032.

BALL LOCKS

BODY ASSEMBLY

SLEEVE SPRINGBP800-023

HOUSINGBP800-022

SLEEVE ASSEMBLY

O'RINGAUS21A026

Figure 2.1 – Housing and Body Assembly


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2.2 Installation of Piston Sub-Assembly

• Using compressed air and a clean rag, thoroughly remove all dust and contamination from the Housing and Piston sub-assemblies - in particular the piston U-seal and the Ø1-3/4” piston bore at the rear of the Housing. Use Acetone to remove oil/grease if necessary. Inspect piston bore for any scoring – remove carefully using fine emery paper (P1200).

• Smear a fine coverage of grease around the circumference of the piston U-seal and insert the Piston sub-assembly into the Housing assembly by inserting the front end of the tube carefully through the brass bush within the housing. Ensure the piston U-seal enters the piston bore properly and without damage.

• Apply a small amount of thread anti-seize compound to the internal thread of the Retainer (BP800-025) and whilst displacing the Sleeve assembly back, screw Retainer onto the end of the Tube at the front of the nozzle. Tighten firmly using tool T800-025. NOTE: ensure threads are not cross-threaded during installation.

• Hold rear of Piston and move back and forward. The movement should be free and smooth, with the force of the sleeve spring quickly forcing the piston and sleeve assemblies forward. Awkward or “jerky” movement may indicate incorrect installation of the piston U-seal or insufficient clearance between the OD of the tube and the mating bore of the brass bush. Remove parts, inspect tube for scoring, and if necessary run a hand ream through the brass bush accurately set to a diameter of 12.85-12.90mm.

BODY SUB-ASSEMBLY

RETAINERBP800-025

SLEEVE SUB-ASSEMBLY

HOUSING SUB-ASSEMBLY

O'RINGAUS21A026

TUBEAUS21A021

PISTON U-SEAL

PISTON SUB-ASSEMBLY

Figure 2.2 – Piston Sub-Assembly Installed NOTE: Whilst not mandatory for new nozzles, a test may be conducted at this point in time to verify the effectiveness of the piston U-seal and sleeve U-seals. Please refer to the test procedure detailed in document T001.


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2.3 Installation of Actuator Sub-Assembly

• Using compressed air and a clean rag, thoroughly remove all dust and contamination from the Actuator sub-assembly and the ball locks at the front of the Body.

• Apply a smear of grease into each of the 8 holes at the front of the Body. Install one Ball Lock (AUS21A038) into each hole.

• Slide Actuator Spring (AUS21A030) over front of Body. • Smear a thin layer of grease around the inside of the Dust Seal within the

back of the Actuator. Slide Actuator sub-assembly over the front of the Body, and using a slow twisting motion, gently force the Actuator back until the Dust Seal rides over the front of the Housing. Take care to ensure the inner lip of the seal does not catch on either the Sleeve Spring or Housing. Whilst holding the Actuator back, install a Stock Ring (AUS21A039) into the groove around the front of the Body in order to retain the Actuator.

ACTUATOR SPRINGAUS21A030

DUST SEALAUS21A028

BALL LOCKSAUS21A038

(8 OF)

STOCK RINGAUS21A039

ACTUATORASSEMBLY

HOUSINGBP800-022

TUBEAUS21A021

RETAINERBP800-025

Figure 2.3 – Front End Assembly


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2.4 Installation of End-Cap and T-Handle Sub-Assemblies

• Using compressed air and a clean rag, thoroughly remove all dust and contamination from both sub-assemblies.

• Mount the nozzle assembly onto jig J800-022-2. Place a drop of Loctite 277 Thread-locker onto 4 Screws (AUS21A011).

• Ensure the Circlip (AUS21A012) is in the required setting within the End-Cap – refer to Fig. 1.6.

• Place the required Piston Spring (Fig. 1.6.1) over the rear of the Piston and securely locate within the counter-bore on the rear face of the Piston. Rotate the rear of the Piston sub-assembly until the Lever Arm (AUS21A018) is inline with the 2” inlet of the Housing.

• Place the Spring Retainer (AUS21A013) over the end (top) of the Piston Spring. Lower the End-Cap assembly over the Spring Retainer and gently force the End-Cap flush onto the mating rear face of the Housing.

NOTE: ensure the Spring Retainer sits squarely and fully onto the Circlip, and that the Piston Spring remains seated within the Spring Retainer.

• Whilst holding the End-Cap against the Housing, fasten both parts together using the 4 Screws.

• Smear a sufficient amount of grease around the Oil Seals on each side of the End-Cap – particularly into the seals themselves.

• Using tool T800-001, centrally locate the broached hole of the Lever Arm between each side of the End-Cap. Place one Brass Bush (AUS21A008) through each side of the End-Cap and over the exposed ends of the tool.

• Place the T-Handle sub-assembly over the End-Cap – refer to Fig. 2.4. Insert the Square Shaft (AUS21A001) through the axis of the T-Handle, forcing out the tool from the other side.

• Install a Washer (AUS21A034) and Screw (AUS21A035) into each end of the Square Shaft. Tighten securely.

• Whilst rotating the T-Handle between the ON and OFF positions, verify the following:

o The action of the Sleeve Spring rapidly returns the T-Handle to the ON position. The action from ON to OFF is smooth.

o The total linear displacement of the Retainer (AUS21A025) should be 21.5-22.5mm between ON and OFF. Insufficient travel may indicate excessive clearance between pins and their mating holes within the Piston sub-assembly, or between the Square Shaft and its mating broached holes through the Lever Arm and T-Handle.

o In the OFF position, the milled flat section at the front of the Catch must fully engage with the cast detent on the underside of the End-Cap at which time the Catch should be in its fully forward position.


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HOUSINGSUB-ASSY

CATCHBP800-006

2" NPT NOZZLE INLETT-HANDLESUB-ASSY

OFF

22.0±0.5NOM.

END CAPSUB-ASSY

CATCHDETENT

BACK SPRING(REFER FIG. 1.6)

SQUARE SHAFTAUS21A001

LEVER ARMAUS21A018

PISTONSUB-ASSY

SPRING RETAINERAUS21A013

CIRCLIPAUS21A012

ON

Figure 2.4 - End-Cap and T-Handle Sub-Assemblies Installed


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• Fuel test the nozzle in accordance with document T004. The purpose of this test is:

o Over 3 consecutive tests, to confirm the required nozzle shut-off setting (Fig. 1.6) has been achieved.

o To detect any fuel leaks from the nozzle, which can subsequently be remedied.

IMPORTANT: Only once the nozzle has been assembled in accordance with this document and has passed the required tests can the nozzle be deemed as a conforming product, suitable for placement into the Store for subsequent sale, trial, or use.


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2.5 Final Tasks

• Attach the Nozzle Plug (AUS21A-P) to the nozzle, by securing the split ring at the end of the lanyard to the lanyard mounting on the underside of the nozzle Housing.

• Attach Sticker onto nozzle Actuator as per Fig. 2.5. NOTE: Additional stickers are prohibited, unless prior authorisation from Banlaw Pty Ltd has been granted.

Figure 2.5.1 – Sticker Placement

• Stamp Serial Code and Model numbers in spaces provided within Plaque A using a 3mm punch set – refer to Fig. 2.5. The Model number can be derived from Table 2.5, whilst the Serial Code is the next available code from the Banlaw Nozzle Tracker software.

Application MINING RAIL HYDRAULIC JN125 Nozzle Code BPM800 BPR800 BPH800 BPJN800

Table 2.5 – Nozzle Models

• The spring setting of the nozzle was determined by the placement of the

Circlip (AUS21A012) and the Piston Spring installed – refer to Fig. 1.6 – and was subsequently confirmed during testing as per document T004. Stamp this setting onto the Housing as shown in Fig. 2.5.

• Record all required information for each nozzle within the Nozzle Tracker software on the workshop PC.

• Complete a Job Card once the requested batch quantity has been fully assembled and tested.

• Place conforming nozzle within plastic bag, and attach the completed tag. Only place nozzle into store once all tasks have been completed.


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Figure 2.5 - Location of Spring Setting Stamping on Nozzle

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. This document and supporting documents ensures every nozzle eligible for use meets such high standards and is entitled to 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: [email protected] www.banlaw.com.au

Distributor & Business Development Manager

Manager – Systems Development & Support

Engineering Manager (Mechanical)

Steve Clayton 0409 045017

[email protected]

John Gregory 0408 492408

[email protected]

Adam Peattie 0412 704838

[email protected]

ALL TEXT SCRIPT SHOWN AS EXAMPLE ONLY USE 3mm PUNCH SET FOR STAMPING PURPOSES

NOZZLE MODEL AND SERIAL CODE

SPRING SETTING

Documents

BPM800 > BPM800 - rev 1