This document forms part of the Assembly Repair and Test M anual for Banlaw Pipeline Quick-Fill Refuelling Nozzles. It describes the equipment and procedures required for the proper flow testing of the nozzles. This information is intended for the use of Banlaw Pipeline Technicians and all Authorised Distributors and Repair Agents.

1.verify the correct shut-off pressure of the nozzle
2.inspect and rectify the nozzle for leaks
3.verify the correct operation of the nozzle, including:

Section 1 details the first option using an in-line ball valve downstream of the nozzle \u2013 item 8. This valve is used to create varying degrees of back pressure against the nozzle thus simulating the pressurisation of a fuel tank.

The objective of the test is to determine the pressure at entry to the nozzle \u2013 measured by item 5 \u2013 that initiates nozzle shut-off. For a given flowrate, there is a limiting inlet pressure that triggers the automatic shut-off mechanism of the nozzle. The exponential relationship between flowrate and inlet pressure is shown on the attached graphs.

IMPORTANT: the fitting used to secure gauge 5 must have a 2\u201d (53\u00b10.5mm) bore and no sudden flow area or directional changes for at least 6 diameters (320mm) upstream of the gauge. This will ensure representative readings are taken. Banlaw can supply upon request a fitting for this purpose.

1.Install nozzle into test circuit and connect to receiver.
2.Start pump with valve 5 fully open.
3.Set flowrate at near maximum
4.Run fuel through nozzle for at least 5 minutes, during which time the nozzle

NOTE: a small volume of fuel (< 50mL) may be lost when disconnecting the nozzle at the completion of flow testing. Such an amount is acceptable and does not constitute a non-conforming nozzle.

7.With pump running, manually turn nozzle off and disconnect from receiver. Turn nozzle on and off several times to check for leaks from front of nozzle and thus confirm whether sleeve maintains liquid tight seal with both the retainer and bore of nozzle body. NOTE: Do NOT point nozzle towards a person\u2019s face during this operation.

cause inconsistent test results due to fluctuations in both diesel viscosity and
density. Thus to ensure consistent and accurate test results are maintained, test
equipment must be calibrated on a regular basis and factors such as diesel
temperature should be monitored during a test and between successive tests.

cap. This is best done with the nozzle disconnected from both the
receiver and test circuit. The action of the handle should be smooth
and consistent through its entire arc. The handle should also readily
spring into the ON position if the catch is released. Such action

indicates a satisfactory and consistent level of friction between seals and their mating surfaces. Check seal integrity andl i ght l y polish bore surfaces with 1200 grit wet & dry grade emery paper if required.

turns of the nozzle back spring. The free length and total number of coils should be within the ranges specified in Table 2.2.2.1. Discard any spring outside these limits. DO NOT ATTEM PT TO RECTIFY

specification may be lengthened to within the correct range by
securely gripping both ends of the spring and simultaneously
extending the spring and twisting the spring anti-clockwise. This
process can be carefully repeated until the spring length is
within the recommended range.

1.The shut-off pressure of a newly assembled nozzle will stabilise to a consistent value after several flow tests. Step 5 states 4-5 tests should be a sufficient number, although the experience of a repair technician will determine when a nozzle has reached its \u201csteady-state\u201d performance

2.The shut-off pressure of a nozzle is very susceptible to variances in the properties of the nozzle back spring. For example, up to 15kPa variation can be caused by only 1.5mm variation in spring free length. Discard any spring whose performance is considered unsatisfactory.