Document Title: Revision No: 1

T001
Description: Air Testing Procedure for All Issue Date: 06/01
Banlaw Refuelling Nozzles

This document forms part of the Assembly Repair and Test Manual for Banlaw Pipeline
Quick-Fill Refuelling Nozzles. It describes the equipment and procedures required for
the air testing of the Piston and Sleeve seals in a nozzle prior to final assembly.

This test is an important step in the proper assembly of a nozzle. Possible faults
detected in these procedures will allow the technician to identify and rectify seal
leakage detrimental to the operation of the nozzle prior to final assembly.

1. Test Rig
To perform this test a simple jig is required. Figure 1.1 below shows the basic test
circuit required to satisfactorily conduct air testing on the nozzle seals. NOTE: The
circuit shown is purely indicative of what is required.

Figure 1.1: Air Test Jig

T001 – Revision 1 1
2. Test Procedure

2.1 Back End of Nozzle – Piston seal

NOTE: Ensure Body Assembly is properly installed onto Housing and Retainer is
tightened onto Tube PRIOR to air testing.

1. Attach partially assembled nozzle to test rig – nozzle end-cap removed.

2. Carefully open air supply valve until air pressure within nozzle reaches
approximately 200kPa
3. Twist nozzle around until piston chamber is vertical. Using a small container
pour approx. 50-60mL of diesel into the rear chamber
4. Check for air bubbles appearing from around seal area. Move Piston up & down
and again check that there are no air bubbles appearing from around seal area.

Test FAIL: The nozzle has failed this test if any air bubbles are detected. Empty diesel
back into container, remove nozzle from test rig. Rectify fault (see below) and retest.

Test PASS: The nozzle has passed this test if no air bubbles are detected.

Empty diesel back into container and proceed with section 2.2.

2.2 Front-end of Nozzle – Sleeve seals

1. Attach partially assembled nozzle to test rig

2. Carefully open air supply valve until air pressure within nozzle reaches
approximately 200kPa
3. Twist nozzle around until nozzle body chamber is vertical. Using a small
container pour approx. 50-60mL of diesel into the body chamber
4. Check for air bubbles appearing from around seal area. Move Piston up & down
and again check that there are no air bubbles appearing from around seal area

Test FAIL: The nozzle has failed this test if any air bubbles are detected. Empty diesel
back into container and remove nozzle from test rig. Rectify fault (see below) and
retest.

Test PASS: The nozzle has passed this test if no air bubbles are detected.

Empty diesel back into container and remove nozzle from test rig.

Possible Causes of Seal Leakage:

• Worn / faulty seal – inspect sealing edge of seal for irregularities
• Scoring within seal bore – particularly if dirt / grit has been within bore
• Incorrect bore size – bore diameter must be ø51.72±0.02mm
Replace any faulty parts prior to resuming assembly of nozzle.

T001 – Revision 1 2