HYDRAU-FLO®

Mechanical and non-pressurised fuel filling valves

Safety Solutions for Liquid Filling

Safe, clean and reliable overfill protection systems

Refuelling rates up to 2100 lpm (550 gpm)

ExcellentMineralsSolutions

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: • Trucks• Loaders • Excavators • Dozers• Diesel powered pumps• Lighting towers

Maritime: • Gantries • Cranes • Lighting towers • Diesel powered pumps • Generators

Oil & Gas: • Trucks • Static tanks • Automated refuelling solutions • Hot fuelling

Industrial: • Diesel powered pumps • Generators • Lighting towers • Static tanks • Transfer stations

Rail: • Locomotives • Storage tanks • Refuelling depots

Hydraulic fracturing application

Road transport application

Rail application

Hydrau-Flo® valve kits are manufactured to suit a wide range of industrial applications

in the mining, construction, oil and gas, rail & maritime sectors. These configurations are

designed for individual equipment needs using our professional engineering design service.

Hydrau-Flo® applications

Mining truck application

Dewatering pump application

Gantry applicationLighting tower application

Mining grader application

Drill application

Mining service truck application

Mining dozer application

Mining excavator application

5

6

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.

TOP: Hydrau-Flo® float control valve HF1008Z0007

LEFT: Hydrau-Flo® fuel filling black valve HF1105Z0001

Hydrau-Flo® system overview

When the float is down fluid bleeds into the tank through the pilot line

With higher pressure on top of the piston the valve remains open

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

• Significantly improves safety and environmental

outcomes

• Ground level refuelling

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

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.

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 Customer response

1. What 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. Make, model and year of manufacture of the machine, and fast fill system if known.

3. What is your required flow rate? (minimum & maximum)

4. What is the fuel tank capacity and material of construction?

5. What size are the inlet and outlets on the tank?

6. Can the tank be welded? (if applicable)

7. Are 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. Supply 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. Do you require installation assistance, or do you have technical personnel on site to complete the installation?

7

8

Hydrau-Flo® selection guideSelect your receiver

Select your fuel filling valve (FFV) - details page 9

Select your adaptor - details page 10

Select your lines and connectors - details page 12

Select your float control valve or lever control valve - details page 9

Black FFV

Blue/Red/Gold

FFV

3/8” Pilot line

1/2” Pilot line

1 1/4” Exhaust

line

3/4” Breather

line

HF1105Z0001

HF1008Z0001

HF1105Z0002

HF1113Z0003 HF1113Z0001 HF1113Z0002

HF1008Z0009

HF1105Z0003

HF1008Z0007

HF1105Z0004 HF1105Z0006

HF1007Z0001 / HF1007Z0002

HF1105Z0007

HF1007Z0003 / HF1007Z0004

HF1105Z0010

HF1007Z0005

HF1103Z0006

HFS27-0604

HFS27-0804

HF1102Z0012 HF1102Z0013

103042

HF1204Z0013 HFS27-0806

HF1215Z0002

102907

102350

HF1011Z0002

HF1204Z0012

HF802-0808

HF1102Z0001

HF1102Z0014

214441

HHT16A

HF1102Z0004

HF1102Z0003

225231

HF1103Z0002

HF1204Z0001

HF805-0808

HF1102Z0002

HF1102Z0007

HF1102Z0014

HF1102Z0008

HF1102Z0009

HF1102Z0003

HF1204Z0003

HFS50-080808

HF1102Z0005

HF1102Z0011

HF1102Z0001

HF802-0606

104074

HF1102Z0015

HF1103Z0003

HF1103Z0004

HF805-0606

HFS8-0409

HF1102Z0010

225232

HF1103Z0003

104073

HFS7-0409

216647

215250

216655

HF1204Z0002

HFT204-0609

HFS27-1212

HHP112

HF1215Z0004

HF1008Z0003 HF0304Z0003HF802-1212 106409 106408 HF1014Z0001 106040 106042 HF1014Z0002

RSC-4347

Hydrau-Flo® valves and breathers

BlACk - FFV For new applications andsome existing applications.• Flow rate to 1000 lpm

(264 gpm)• Valve mounting 3” NPS• Male o-ringHF1105Z0001

STANDARD 2” - FCVIncorporates rollover shut-off protectionand anti-surge.• Tank fill rate to 1000 lpm (264 gpm)• Valve mounting 2” NPT maleHF1008Z0001

Stationary equipment only, skid mountedpump sets, generators & lighting plants.• Valve mounting stem 7/8” UNF• Working pressure up to 5 barHF1007Z0001 - 110mm Stem HF1007Z0002 - 250mm Stem

Anti-surge breather has the same functionsas fuel control valves including rollover protection• Tank fill rate to 1000 lpm (264gpm)• Valve mounting 2” NPT maleHF1008Z0002

Stationary equipment only, remote &gravity filling from an auxiliary fuel tank.• Valve mounting stem 7/8” UNF• Working pressure up to 20 barHF1007Z0003 - 110mm Stem HF1007Z0004 - 250mm Stem

Anti-surge breather with filter option has thesame functions as the fuel control valves including rollover protection. Provides filtered air to preventfuel contamination. Capable of environmentalfiltering to 3 micron.• Tank fill rate to 1000 lpm (264gpm)• Valve mounting 2” NPT maleHF1008Z0010

Mobile / stationary equipment, skid mountedpump sets, generators & lighting plants.• Valve mounting stem 7/8” UNF• Working pressure up to 90 barHF1007Z0005 - 110mm Stem

1 ½” OPTION - STANDARD - FCVIncorporates rollover shut-off protectionand anti-surge.• Tank fill rate to 1000 lpm (264 gpm)• Valve mounting 11/2” NPT maleHF1008Z0009

STANDARD 2” - FCV - wITH BREATHER OPTIONProvides filtered air to prevent fuelcontamination.Capable of environmental filtering to 3micron.• Tank fill rate to 1000 lpm (264 gpm)• Filtration 3 micron• Valve mounting 2” NPT maleHF1008Z0007 (std) / HF1008Z0008 (short)

RED - FFVZNC3 Recess.• Flow rate to 800 lpm (211 gpm)• Valve mounting 11/2” NPT

maleHF1105Z0002

BlUE - FFVRetro fit for direct mounting to equipment tanks with 2” NPT female fittings.• Flow rate to 800 lpm (211 gpm)• Valve mounting 2” NPT

maleHF1105Z0003

BlUE - FFVFor compact machinery andunderground applications.• Flow rate to 800 lpm (211 gpm)• Valve mounting 11/2” NPT

maleHF1105Z0004

GOlD - 1” - FFV• Flow Rate to 80 lpm

(21 gpm)• Valve mounting 1” NPT

maleHF1105Z0006

GOlD - 2” - FFV• Flow rate to 800 lpm

(211 gpm)• Valve mounting 2” NPT

maleHF1105Z0007

ORANGE - FFV• Flow rate to 1500 lpm

(396 gpm)• Valve Mounting 4” NPT

maleHF1105Z0010

Fuel Filling Valves Float Control Valves

lever Float Control Valve

Anti-Surge Breathers

9

10

Hydrau-Flo® Black Fuel Filling ValveHF1105Z0001 • Valve mounting - 3” NPS male o-ring seal.• Fuel connection - 2” NPT female.

Black FFV to 2” NPT maleHF1102Z0001

Designed for use with komatsu D375102350

Designed for use with CAT fuel tankHF1102Z0008

Designed for use with Hitachi EX 3600-6215250

Designed for use with liebherr 994 / 996HF1102Z0007

Designed for use with John Deere fuel tank216647

Designed for use with CAT 16M 12 bolt flange fuel tank225232

Black FFV to2” hose tailHF1102Z0014Aluminium

Black FFV to weld-in flush mount C/w flangeHF1102Z0010

Black FFV to weld-on ringHF1102Z0002

Black FFV to 2 ½” hose tailHF1102Z0005 Steel

Black FFV to weld-on stand pipeHF1102Z0012 - 150mmHF1102Z0013 - 310mm

Black FFV to 2” SAE code 61225231

Black FFV to2” BSPT male102907

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

Black FFV to2” hose tailHF1102Z0004 Steel

Black FFV to 2 ½” hose tailHF1102Z0015 Aluminium

Black FFV to aluminium weld-on flangeHF1102Z0014 Aluminium

Hydrau-Flo® adaptors selection

Hydrau-Flo® adaptors for use with komatsu

equipment

Hydrau-Flo® adaptors for use with CAT

equipment

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

General

Designed for use with komatsu 830e /930eHF1102Z0003

Designed for use with Hitachi EH 4000103042

Designed for use with liebherr 994 / 996HF1102Z0009 Black FFV to 2” NPT male

Designed for use with CAT D10R / D11R FuelInlet 2” NPT male to 2” SAE Code 61HF1103Z0003

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

Designed for use with CATD10R / D11RFuel tankHF1102Z0001

Designed for use with CAT D10R / D11R Fuel TankHF1103Z0004

Designed for use with CAT D10R / D11RFuel inlet 2” NPT male to 2” SAE Code 61HF1103Z0003

Designed for use with komatsu830e / 930eHF1102Z0003

4 Bolt - weld on float and breather mountHF1012Z0001

4 Bolt bolt-on float and breather mount7/8” UNF female thread (lever float) 3/4” BSPT female thread (breather std pipe HF101470001, breather HF0304Z0003)HF1012Z0002

Used with HF1012Z0002 or HF1012Z0003

Used with HF1014Z0001 Used with HF1012Z0002 Used with HF1012Z0002 or HF1012Z0003

Used with HF1012Z0001 or HF1103Z0001 Used with HF1103Z0001

Used with HF1012Z0001 or HF1103Z0001

Designed for use with John Deere Fuel tank216655

Breather3/4” BSPT male threadHF0304Z0003

4 Bolt bolt-on float mount 7/8” UNF female threadHF1012Z0003

4 Bolt screw-in float and breather mount2” NPT male threadHF1103Z0001

weld on socket2” NPT female threadHF1011Z0002

Breather stand pipe 3/4” BSPT male x 3/4” BSPT female threadHF1014Z0001

Hydrau-Flo® adaptors for use with wiggins equipment

Hydrau-Flo® adaptors for use with CAT equipment

Hydrau-Flo® adaptors for use with John Deere equipment

Hydrau-Flo® adaptors for use with komatsu equipment

Designed for use with wigginsZNC3 / ZNC4Bolt-on / weld-onflush mountHF1103Z0006

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.

Socket 2” NPTHF1011Z0002

weld in recessedAdaptor 2” NPT femaleHF1103Z0002

General

12

3/8” Pilot line

Pilot line hose, fittings and accessories

Hydrau-Flo® lines and connectors

Nipple reducing3/8” BSPT M x 1/4”BSPT maleHFS27-0604

Nipple reducing1/2” BSPT male x 1/4” BSPT maleHFS27-0804

1/4” plugUsed for pluggingunused pilot lineportHF1204Z0003

Tee male3/8” BSPT maleHF1204Z0012

Tee male1/2” BSPT maleHFS50-080808

Elbow 90 deg male9/16” JIC male x 1/4”BSPT maleHFS8-0409

Pilot line check valve3/8” BSPT female x 3/8” BSPT femaleHF1204Z0002Used where 2 x filling valves are connected to 1 x float control valve. Includes balancing port.

Swivel hose tail3/8” BSPP female x 3/8” hose tailHF802-0606

Swivel hose tail1/2” BSPP female x 1/2” hose tailHF802-0808

3/8” Push on pilotline hoseSingle wire braidHHT16A

Pilot lineMagnetic anchorSuit 3/8” hose (16.5mmto 18mm hose OD)68kg (150 lbs) pull force104073

Pilot lineMagnetic anchorSuit 1/2” hose (20mmto 22mm hose OD)68kg (150 lbs) pull force104074

3/8” hose crimpCoupling9/16” JIC male x 3/8”hose crimpHFT204-0609

Adaptor3/8” BSPT female x 1/4” BSPT maleHF1204Z0013

Elbow 90 deg femaleSwivel hose tail3/8” BSPP female x 3/8” hose tailHF805-0606

Elbow 90 deg femaleSwivel hose tail1/2” BSPP female x 1/2” hose tailHF805-0808

Pilot line check valve3/8” BSPT female x 3/8” BSPT femaleHF1204Z0001Used where 1 x lever float valve is connected to 2 x fuel filling valves.

Nipple Reducing9/16” JIC male x1/4” BSPT maleHFS7-0409

1/2” push on pilotline hoseSingle textile braidHF1215Z0002

Nipple reducing3/8” BSPT male x 1/2” BSPT maleHFS27-0806

1/2” Pilot line

3/4” Breather line

1 1/4” Exhaust line

Exhaust line Float Control Valves & Breathershose, fittings and accessories

Nipple3/4” BSPT male x 3/4” BSPT maleHFS27-1212

1 1/4” push on exhaust line hoseSingle textile braidSuit all green float valves & breathersHF1215Z0004

Steel rain capBreather3/4” BSPT maleHF0304Z0003

Elbow 90 degFemale / male3/4” BSFT female x 3/4” BSPT male106408

Nylon air breather3 micron3/4” NPT maleBuilt in restriction indicator and replaceable element106042

Swivel hose tail3/4” BSPP female x 3/4” hose tailHF802-1212

1 1/4” hose clampSingle textile braidRSC-4347

3/4” push on pilotline hoseSingle textile braidHHP112

Barrel mipple3/4” BSPT maleFor mounting HF0304Z003Rain cap breatherHF1014Z0001

Bracket weld-on /bolt-on3/4” BSPT maleSuit rain cap HF0304Z0003HF1014Z0002

Hose tail3/4” BSPT male x 3/4” hose tail106409

Steel air breather3 micron3/4” NPT male106040

Breather mountingFlange3/4” BSPT male to anti-surge breatherHF1008Z0003

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Hydrau-Flo® valves dimensions

Fuel filling valves (FFV)

Float control valves (FCV)

lever float control valves

Anti-Surge Breathers (ASB)

S = 48 + 11 + T

S = SETTING DISTANCET = THICKNESS OF FUEL TANK MATERIAL

Eg. 48 + 11 + 6 = 65mm

48

SET WITH FLOAT CLOSED

266mm (10.4”)

129mm (5”)

115mm (4.5”)115mm (4.5”)2”NPT2”NPT

220m

m (

8.8”

)

122m

m (

4.8”

)

HF1008Z0010HF1008Z0002

FLOAT CLOSED

FLOAT OPEN11

6 (T

)

65 (

S)

15

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.

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Weir Minerals Multiflo 15 Dacmar Road Coolum Beach QLD 4573 Australia

T +61 (0)7 5449 3000 F +61 (0)7 5449 4304

multiflo@weirminerals.com www.weirminerals.com

Weir Minerals Multiflo is a business unit of Weir Minerals Australia Ltd.

ExcellentMineralsSolutions