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HYDRAU-FLO®
Safety Solutions for Liquid Filling
Excellent
Minerals
Solutions
Mechanical and non-pressurised fuel filling valves
Safe, clean and reliable
overfill protection systems
Refuelling rates up to 2100 lpm (550 gpm)
Contents
Deliverables.............................................................................. 3
Global references................................................................... 4
Applications............................................................................. 5
System overview.................................................................... 6
Selection table ....................................................................... 7
Selection guide....................................................................... 8
Valves and breathers............................................................. 9
Adaptors selection............................................................... 10
Lines and connectors............................................................12
Valve dimensions.................................................................. 14
3
Hydrau-Flo® deliverables
Non-pressure refuelling is industries’ best practice
• Low cost solution
•Increases filling times by up to 83%, adding thousands of production hours to equipment fleets*
• Prevents overfilling, fuel spillage and waste
• Removes the operator from influencing fill levels
• Helps to eliminate fuel theft
Greatly improves safety and environmental outcomes
•Removes the risk of tank ruptures from pressure build up during and after filling
• Removes fuel spray associated with pressurised systems
• Minimises the risk of fire from fuel spillages
• Removes operator from the hot/red zone
• Allows for hot refuelling
• Allows for ground level refuelling
Tested and proven for 15 years
•Based on a proven mechanical principle of spring opposed hydraulic pressure
• Comprehensive 3 year warranty
• Simple installation
• Minimal maintenance
•Proven in extreme temperatures - 65°C (-85°F) with Environmental Exposure Certification
•Install base of over 30,000 units
• CE certified
*83% is based on calculated time savings for refuelling a fleet of Rubber Tyred Gantry Cranes
4
Hydrau-Flo® global references
Mining:
Oil & Gas:
Rail:
•Trucks
•Loaders
•Excavators
•Dozers
• Diesel powered pumps
• Lighting towers
•
•
•
•
•Locomotives
• Storage tanks
• Refuelling depots
Maritime:
•Gantries
•Cranes
• Lighting towers
• Diesel powered pumps
•Generators
Frac trucks
Static tanks
Automated refuelling solutions
Hot fuelling
Industrial:
• Diesel powered pumps
•Generators
• Lighting towers
• Static tanks
• Transfer stations
5
Hydrau-Flo® applications
Hydrau-Flo® valve kits are manufactured to suit a wide range of industrial applications
in the mining, oil and gas, transport, construction & maritime sectors. These configurations
are designed for individual equipment needs using our professional engineering design service.
Mining truck
application
Mining excavator
application
Mining dozer
application
Mining grader
application
Drill
application
Mining service
truck application
Dewatering pump
application
Lighting tower
application
Gantry application
Hydraulic fracturing
application
Road transport
application
Rail application
6
Hydrau-Flo® system overview
The Hydrau-Flo® valve system is a safe, clean and reliable fuel filling valve arrangement
which removes the risk of overfilling, spillage and tank rupture while minimising safety
and environmental hazards associated with fuel transfer.
With higher pressure on top of the piston
the valve remains open
TOP: Hydrau-Flo® float
control valve
HF1008Z0007
LEFT: Hydrau-Flo® fuel filling
black valve HF1105Z0001
When the float is down fluid bleeds
into the tank through the pilot line
Hydrau-Flo® fuel filling
valve system:
• Flow rates up to 2100 lpm (555 gpm)
• Hydraulically actuated
• Operates on fluid level not pressure
•Used in conjunction with existing fast fill systems
• Prevents overfilling
• Prevents fuel spillage and wastage
•Removes the risk of tank rupture due to pressure
build up during and after filling
•Minimises the risk of fire as a result of fuel spillage
•Reduces costs associated with fuel wastage and
equipment damage
Hydrau-Flo® system solution:
•System depends on fluid level, not tank pressure, and
cannot be overridden
•Fuel enters through the standard fast fill receiver and
Hydrau-Flo® fast filling valve
•A small portion of the flow is re-directed through a
pilot line to the float control valve
•Once the desired fuel level in the tank is reached, the
flow will be shut off
•The fuel in the pilot line now applies equal pressure to
the back of the fast filling valve
•The spring in the fast filling valve now acts as the
differential closing off the piston
•Significantly improves safety and environmental
outcomes
• Ground level refuelling
For a more detailed description and presentation please scan this barcode into your mobile device.
Alternatively please visit www.weirminerals.com/hydrauflo to watch the video.
7
Hydrau-Flo® valves selection table
What are the main drivers for this insallation? (Mark boxes 1 to 6 in order of priority)
Fast filling
Overfill protection
Fuel theft
Trickle feed
Fuel surge
Zero spill compliance
Requirement for criteria
1.
W
hat equipment (stationary or mobile) is the Hydrau- Flo® valve
system to be fitted to? Is it a trickle feed system or fast fill
requirement?
2. M
ake, model and year of manufacture of the machine, and fast fill
system if known.
3. W
hat is your required flow rate? (minimum & maximum)
4. W
hat is the fuel tank capacity and material of construction?
5. W
hat size are the inlet and outlets on the tank?
6. Can the tank be welded? (if applicable)
7. A
re fuel inlets required on either side of the machine?
8. Is simultaneous dual or triple filling needed?
9. A
capillary line which connects the tank inlet and outlet can be run
internally or externally. Which is preferred? Magnet anchors are
available for steel tanks (3/8” 104073 and 1/2” 104074)
10. S
upply a drawing and/or photos of the fuel tank? (the more
the better)
11. How many Hydrau- Flo® kits do you require?
12. Is this enquiry for a single piece of equipment or multiple pieces of
equipment?
13. If the application is for trickle feed, is redundancy required?
Use anti-surge breather HF1008Z0002.
14. Any further information regarding the tank?
15. Shipping location (city, state, country)
16. Timing of project (when do you expect to require the system)?
17. D
o you require installation assistance, or do you have technical
personnel on site to complete the installation?
Customer response
8
Hydrau-Flo® selection guide
Select your receiver
HF1113Z0003
Banlaw (light)
HF1113Z0002
Wiggins (5 PSI)
HF1113Z0001
Select your fuel filling valve (FFV) - details page 9
HF1105Z0001
HF1105Z0003
HF1105Z0002
HF1105Z0004
HF1105Z0006
HF1105Z0007
HF1105Z0010
Select your adaptor - details page 10
102907
HF1102Z0004
HF1102Z0014
HF1102Z0005
102350
HF1102Z0008
HF1102Z0011
HF1103Z0003
HF1102Z0001
225231
HF1102Z0009
HF1102Z0015
HF1102Z0010
216647
HF1102Z0012
HF1102Z0013
209304
HF1102Z0002
Black FFV
Blue/
Red/Gold
FFV
HF1103Z0006
HF1103Z0002
HF1011Z0002
HF1102Z0003
225232
HF1011Z0001
215249
214441
103042
HF1103Z0003
HF1103Z0004
HF1102Z0007
216655
Select your lines and connectors - details page 12
3/8”
Pilot line
HFS27-0604 HF1204Z0012
HF1204Z0001
HF1204Z0003 HF802-0606
HF805-0606
104073
HF1204Z0002
HF1204Z0013 HFS27-0806
HHT16A
1/2”
Pilot line
3/4”
Breather
line
HFS27-0804
HF802-0808
HF805-0808
104074
HFS8-0409
HFS7-0409
HFT204-0609
HF1215Z0002
HFS27-1212
HF802-1212
106409
106408
HF1014Z0001
106040
106042
HF1014Z0002
HF1008Z0003
HF0304Z0003
HHP112
1 1/4”
Exhaust
line
RSC-4347
HF1215Z0004
Select your float control valve or lever control valve - details page 9
HF1008Z0001
HF1008Z0009
HF1008Z0007
HF1007Z0001 / HF1007Z0002
HF1007Z0003 / HF1007Z0004
HF1007Z0005
9
Hydrau-Flo® valves and breathers
Fuel Filling Valves
Black - FFV
For new applications and
some existing applications.
• F low rate to 1000 lpm
(264 gpm)
• Valve mounting 3” NPS
• Male o-ring
HF1105Z0001
RED - FFV
ZNC3 Recess.
• Flow rate to 800 lpm
(211 gpm)
•Valve mounting 2” NPT
male
HF1105Z0002
BLUE - FFV
Retro fit for direct mounting
to equipment tanks with 2”
NPT female fittings.
• Flow rate to 650 lpm
(171 gpm)
•Valve mounting 2” NPT
male
Float Control Valves
STANDARD 2” - FCV
Incorporates rollover shut-off protection
and anti-surge.
•Tank fill rate to 1000 lpm (264 gpm)
•Valve mounting 2” NPT male
HF1008Z0001
1 ½” OPTION - STANDARD - FCV
Incorporates rollover shut-off protection
and anti-surge.
•Tank fill rate to 1000 lpm (264 gpm)
•Valve mounting 1 1/2” NPT male
HF1008Z0009
STANDARD 2” - FCV - with
breather option
Provides filtered air to prevent fuel
contamination.
Capable of environmental filtering to 3
micron.
• Tank fill rate to 1000 lpm (264 gpm)
• Filtration 3 micron using external filter
• Valve mounting 2” NPT male
HF1008Z0007 (std) / HF1008Z0008 (short)
Lever Float Control Valve
HF1105Z0003
Stationary equipment only, skid mounted
pump sets, generators & lighting plants.
BLUE - FFV
• Valve mounting stem 7/8” UNF
• Working pressure up to 1.5 bar
For compact machinery and
underground applications.
• Flow rate to 650 lpm
(171 gpm)
•Valve mounting 1 1/2” NPT
male
HF1105Z0004
Gold - 1” - FFV
•Flow Rate to 80 lpm
(21 gpm)
•Valve mounting 1” NPT
male
HF1105Z0006
HF1007Z0001 - 110mm Stem
HF1007Z0002 - 250mm Stem
Stationary equipment only, remote &
gravity filling from an auxiliary fuel tank.
• Valve mounting stem 7/8” UNF
• Working pressure up to 20 bar
HF1007Z0003 - 110mm Stem
HF1007Z0004 - 250mm Stem
Mobile / stationary equipment, skid mounted
pump sets, generators & lighting plants.
• Valve mounting stem 7/8” UNF
• Working pressure up to 90 bar
HF1007Z0005 - 110mm Stem
Anti-Surge Breathers
Gold - 2” - FFV
•Flow rate to 800 lpm
(211 gpm)
•Valve mounting 2” NPT
male
HF1105Z0007
ORANGE - FFV
•Flow rate to 1500 lpm
(396 gpm)
•Valve Mounting 4” NPT
male
HF1105Z0010
Anti-surge breather has the same functions
as float control valves including rollover
protection and fuel anti-surge.
• Tank fill rate to 1000 lpm (264gpm)
• Valve mounting 2” NPT male
HF1008Z0002
Anti-surge breather with filter option has the
same functions as the float control valves including
rollover protection. Provides filtered air to prevent
fuel contamination. Capable of environmental
filtering to 3 micron.
• Tank fill rate to 1000 lpm (264gpm)
• Valve mounting 2” NPT male
HF1008Z0010
10
Hydrau-Flo® adaptors selection
Hydrau-Flo® Black Fuel Filling Valve
HF1105Z0001
• Valve mounting - 3” NPS male o-ring seal.
•Fuel connection - 2” NPT female.
General
Black FFV to
2” NPT male
HF1102Z0001
Black FFV to
2” BSPT male
102907
Black FFV to
2” hose tail
HF1102Z0004 Steel
Black FFV to
2” hose tail
HF1102Z0014
Aluminium
Black FFV to
2 ½” hose tail
HF1102Z0005 Steel
Black FFV to
2 ½” hose tail
HF1102Z0015
Aluminium
Black FFV to
weld-in flush mount
C/W flange
HF1102Z0010
Black FFV to weld-on
stand pipe
HF1102Z0012 - 150mm
HF1102Z0013 - 310mm
Black FFV to
aluminium weld-on
flange
209304
Aluminium
Black FFV to
weld-on ring
HF1102Z0002
Black FFV to 2” SAE
code 61
225231
Hydrau-Flo® adaptors
for use with Komatsu
equipment
Designed for use
with Komatsu d375
102350
Hydrau-Flo® adaptors
for use with CAT
equipment
Designed for use
with CAT fuel tank
HF1102Z0008
Designed for use with
CAT D10R / D11R Fuel
Inlet 2” NPT male to
2” SAE Code 61
HF1103Z0003
Designed for use
with CAT 16M 12 bolt
flange fuel tank
225232
Hydrau-Flo® adaptors
for use with Hitachi
equipment
Hydrau-Flo® adaptors
for use with Liebherr
equipment
Hydrau-Flo® adaptors
for use with John
Deere equipment
215249
Designed for use with
Liebherr 994 / 996
HF1102Z0007
Designed for use with
John Deere fuel tank
216647
Designed for use
with Hitachi EX
3600-6
215189
Designed for use with
Liebherr 994 / 996
HF1102Z0009
Black FFV to 2” NPT male
Designed for use with
Hitachi EH 4000
103042
Designed for use with
Liebherr Black FFV to 2’
SAE Code 61 HF1102Z0011
Designed for use with
Liebherr Black FFV to
2 1/2” NPT female 214441
11
Hydrau-Flo® Blue Fuel Filling Valve HF1105Z0003
Hydrau-Flo® Gold Fuel Filling Valve HF1105Z0007
Hydrau-Flo® Red Fuel Filling Valve HF1105Z0002
• Valve mounting - 2” NPT male.
•Fuel connection - 2” NPT female.
General
Weld in recessed
Adaptor 2” NPT
female
HF1103Z0002
Socket 2” NPT
HF1011Z0002
Hydrau-Flo® adaptors for use with
Komatsu equipment
Hydrau-Flo® adaptors for use with
CAT equipment
Designed for use
with Komatsu
830e / 930e
HF1102Z0003
Hydrau-Flo® adaptors for use with
John Deere equipment
Designed for use
with CAT
D10R / D11R
Fuel tank
HF1011Z0001
Designed for
use with CAT
D10R / D11R
Fuel Tank
HF1103Z0004
Designed for use
with John Deere
Fuel tank
216655
Hydrau-Flo® adaptors for use with
Wiggins equipment
Designed for use
with CAT D10R / D11R
Fuel inlet 2” NPT male
to 2” SAE Code 61
HF1103Z0003
Designed for use
with Wiggins
ZNC3 / ZNC4
Bolt-on / weld-on
flush mount
HF1103Z0006
Hydrau-Flo® Lever Float Control Valve
HF1007Z0001/HF1007Z0002
Hydrau-Flo® Lever Float Control Valve
HF1007Z0003/HF1007Z0004
Hydrau-Flo® Lever Float Control Valve
HF1007Z0005
• Valve mounting - 7/8” UNF male thread o-ring seal
•Pilot line connection - 1/4” BSPT male thread
4 Bolt - weld on float
and breather mount
HF1012Z0001
Used with HF1012Z0002 or HF1012Z0003
Breather
3/4” BSPT male thread
HF0304Z0003
Used with HF1014Z0001
Breather stand pipe
3/4” BSPT male x 3/4”
BSPT female thread
HF1014Z0001
Used with HF1012Z0002
4 Bolt bolt-on float and breather mount
7/8” UNF female thread (lever float) 3/4” BSPT female thread
(breather std pipe HF101470001, breather HF0304Z0003)
HF1012Z0002
Used with HF1012Z0001 or HF1103Z0001
4 Bolt bolt-on float
mount 7/8” UNF
female thread
HF1012Z0003
Used with HF1012Z0001 or
HF1103Z0001
4 Bolt screw-in float
and breather mount
2” male thread
HF1103Z0001 NPT
221479
BSP
Used with HF1012Z0002 or
HF1012Z0003
Weld on socket
2” NPT female thread
HF1011Z0002
Used with HF1103Z0001
12
Hydrau-Flo® lines and connectors
Pilot Line
hose, fittings and accessories
3/8” Pilot Line
Elbow 90 deg female
Swivel hose tail
3/8” BSPP female x
3/8” hose tail
HF805-0606
Nipple reducing
3/8” BSPT M x 1/4”
BSPT male
HFS27-0604
Swivel hose tail
3/8” BSPP female x
3/8” hose tail
HF802-0606
Tee male
3/8” BSPT male
HF1204Z0012
Pilot line
Magnetic anchor
Suit 3/8” hose (16.5mm
to 18mm hose OD)
68kg (150 lbs) pull
force
104073
Pilot line check valve
3/8” BSPT female x
3/8” BSPT female
HF1204Z0001
Adaptor
3/8” BSPT female x
1/4” BSPT male
HF1204Z0013
Nipple reducing
3/8” BSPT male x
1/2” BSPT male
HFS27-0806
Pilot line check valve
3/8” BSPT female x 3/8”
BSPT female
HF1204Z0002
Used where 2 x filling valves
are connected to 1 x float
control valve. Includes
balancing port.
1/4” plug
Used for plugging
unused pilot line
port
HF1204Z0003
Used where 1 x lever
float valve is connected
to 2 x fuel filling valves.
3/8” Push on pilot
line hose
Single wire braid
HHT16A
1/2” Pilot Line
Nipple reducing
1/2” BSPT male x
1/4” BSPT male
HFS27-0804
Swivel hose tail
1/2” BSPP female x
1/2” hose tail
HF802-0808
Elbow 90 deg female
Swivel hose tail
1/2” BSPP female x
1/2” hose tail
HF805-0808
TEE male
1/2” BSPT male
HFS50-080808
Pilot line
Magnetic anchor
Suit 1/2” hose (20mm
to 22mm hose OD)
68kg (150 lbs) pull
force
104074
Nipple Reducing
9/16” JIC male x
1/4” BSPT male
HFS7-0409
Elbow 90 deg male
9/16” JIC male x 1/4”
BSPT male
HFS8-0409
3/8” hose crimp
Coupling
9/16” JIC male x 3/8”
hose crimp
HFT204-0609
1/2” push on pilot
line hose
Single textile braid
HF1215Z0002
13
3/4” Breather Line
Nipple
3/4” BSPT male x
3/4” BSPT male
HFS27-1212
Swivel hose tail
3/4” BSPP female x
3/4” hose tail
HF802-1212
Hose tail
3/4” BSPT male x
3/4” hose tail
106409
Elbow 90 deg
Female / male
3/4” BSFT female x
3/4” BSPT male
106408
Barrel nipple
3/4” BSPT male
For mounting
HF0304Z003
Rain cap breather
HF1014Z0001
Steel air breather
3 micron
3/4” NPT male
106040
Nylon air breather
3 micron
3/4” NPT male
Built in restriction
indicator
106042
Replaceable element
106043
Bracket weld-on /
bolt-on
3/4” BSPT male
(Suit rain cap
HF0304Z0003)
HF1014Z0002
Breather mounting
Flange
3/4” BSPT male to
anti-surge breather
HF1008Z0003
Steel rain cap
Breather
3/4” BSPT male
HF0304Z0003
3/4” push on pilot
line hose
Single textile braid
HHP112
Exhaust Line Float Control Valves & Breathers
hose, fittings and accessories
1 1/4” Exhaust Line
1 1/4” push on exhaust
line hose
Single textile braid
Suit all green float
valves & breathers
HF1215Z0004
1 1/4” hose clamp
Single textile braid
RSC-4347
Hydrau-Flo® installantion tools
Hydrau-Flo® float
control valve install
tool - side entry
200629
Hydrau-Flo® fuel filling
(blue and black) valve
install tool - side entry
201240
Hydrau-Flo® fuel
filling red valve
install tool
202125
Hydrau-Flo® fuel filling
(blue and black) valve
install tool - top entry
101023
Hydrau-Flo®
Tool kit
103628
14
Hydrau-Flo® valves dimensions
Fuel filling valves (FFV)
HF1105Z0006
HF1105Z0007
HF1105Z0002
HF1105Z0003
126mmØ
Ø100 (3.93”)
(4.9ӯ)
3” NPS
70 (2.75”)
4” NPT
117 (4.6”)
133 (5.2”)
(1.9”)
50mm
1/4” BSPT
104mmØ
(4ӯ)
HF1105Z0010
HF1105Z0001
Float control valves (FCV)
HF1008Z0006
HF1009Z0001
HF1008Z0001
HF1008Z0007
15
Lever float control valves
HF1007Z0005
HF1007Z0001
HF1007Z0002
HF1007Z0003
FLOAT CLOSED
S = 48 + 11 + T
65 (S)
6 (T)
48
11
FLOAT OPEN
SET WITH FLOAT CLOSED
S = SETTING DISTANCE
T = THICKNESS OF FUEL TANK MATERIAL
HF1007Z0004
Eg. 48 + 11 + 6 = 65mm
Anti-Surge Breathers (ASB)
266mm (10.4”)
122mm (4.8”)
220mm (8.8”)
129mm (5”)
2”NPT
115mm (4.5”)
HF1008Z0002
HF1008Z0002
2”NPT
115mm (4.5”)
HF1008Z0010
HF1008Z0010
Weir Minerals Multiflo
15 Dacmar Road
Coolum Beach QLD 4573 Australia
T +61 (0)7 5449 3000
F +61 (0)7 5449 4304
Excellent
Minerals
Solutions
[email protected]
www.weirminerals.com
Weir Minerals Australia Ltd. All rights reserved. WARMAN is a trademark and/or registered trademark of Weir Minerals Australia Ltd and Weir Group African IP Ltd; CAVEX,
HYDRAU-FLO and MULTIFLO are trademarks and/or registered trademarks of Weir Minerals Australia Ltd; GEHO is a trademark and/or registered trademark of Weir Minerals
Netherlands bv; FLOWAY is a trademark and/or registered trademark of Weir Floway Inc.; VULCO is a trademark and/or registered trademark of Vulco SA; ISOGATE is a trademark
and/or registered trademark of Weir do Brasil Ltda.; LINATEX is a trademark and/or registered trademark of Linatex Ltd; ENDURON is a trademark and/or registered trademark of
Weir Minerals Europe Ltd; WEIR is a trademark and/or registered trademark of Weir Engineering Services Ltd. KOMATSU, CAT, HITACHI, LIEBHERR, JOHN DEERE and WIGGINS are not
trademarks belonging to any company forming part of The Weir Group PLC.
* KHD is a Humboldt Wedag GmbH brand used under license by The Weir Group.
Issued June 2014
Weir Minerals Multiflo is a business unit of Weir Minerals Australia Ltd.