Safe, clean and reliable overfill protection systems. HYDRAU-FLO Safety Solutions for Liquid Filling

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1 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)

2 Contents Deliverables... 3 Global references...4 Applications... 5 System overview... 6 Selection table... 7 Selection guide... 8 Valves and breathers... 9 Adaptors selection Lines and connectors...12 Valve dimensions... 14

3 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 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: Frac 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

5 5 Hydrau-Flo s Hydrau-Flo valve kits are manufactured to suit a wide range of industrial s 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 Mining excavator Mining dozer Mining grader Drill Mining service truck Dewatering pump Lighting tower Gantry Hydraulic fracturing Road transport Rail

6 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 When the float is down fluid bleeds into the tank through the pilot line LEFT: Hydrau-Flo fuel filling black valve HF1105Z0001 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 to watch the video.

7 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 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/ and 1/ ) 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 is for trickle feed, is redundancy required? Use anti-surge breather HF1008Z 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?

8 8 Hydrau-Flo selection guide Select your receiver HF1113Z0003 Banlaw (light) HF1113Z0001 HF1113Z0002 Wiggins (5 PSI) Select your fuel filling valve (FFV) - details page 9 HF1105Z0001 HF1105Z0002 HF1105Z0003 HF1105Z0004 HF1105Z0006 HF1105Z0007 HF1105Z0010 Select your adaptor - details page HF1102Z0004 HF1102Z0014 HF1102Z0005 HF1102Z0015 HF1102Z HF1102Z0012 HF1102Z HF1102Z0002 Black FFV HF1102Z0008 HF1102Z0011 HF1103Z HF1102Z0007 HF1102Z HF1102Z0009 Blue/ Red/Gold FFV HF1103Z0006 HF1011Z0002 HF1103Z0002 HF1102Z0003 HF1011Z0001 HF1103Z0004 HF1103Z Select your lines and connectors - details page 12 3/8 Pilot line HFS HF1204Z0012 HF1204Z0001 HF1204Z0003 HF HF HF1204Z0002 HF1204Z0013 HFS HHT16A 1/2 Pilot line HFS HF HF HFS HFS HFT HF1215Z0002 3/4 Breather line HFS HF HF1014Z HF1014Z0002 HF1008Z0003 HF0304Z0003 HHP /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 9 Hydrau-Flo valves and breathers Fuel Filling Valves Black - FFV For new s and some existing s. Flow 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 HF1105Z0003 BLUE - FFV For compact machinery and underground s. Flow rate to 650 lpm (171 gpm) Valve mounting 11/2 NPT male HF1105Z0004 Gold FFV Flow Rate to 80 lpm (21 gpm) Valve mounting 1 NPT male HF1105Z0006 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 HF1008Z ½ OPTION - STANDARD - FCV Incorporates rollover shut-off protection and anti-surge. Tank fill rate to 1000 lpm (264 gpm) Valve mounting 11/2 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 Stationary equipment only, skid mounted pump sets, generators & lighting plants. Valve mounting stem 7/8 UNF Working pressure up to 1.5 bar HF1007Z mm Stem HF1007Z mm Stem Stationary equipment only, remote & gravity filling from an auxiliary fuel tank. Valve mounting stem 7/8 UNF Working pressure up to 20 bar HF1007Z mm Stem HF1007Z mm Stem Mobile / stationary equipment, skid mounted pump sets, generators & lighting plants. Valve mounting stem 7/8 UNF Working pressure up to 90 bar HF1007Z mm Stem Anti-Surge Breathers Gold FFV Flow rate to 800 lpm (211 gpm) Valve mounting 2 NPT male HF1105Z0007 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 ORANGE - FFV Flow rate to 1500 lpm (396 gpm) Valve Mounting 4 NPT male HF1105Z0010 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 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 2 NPT male HF1102Z BSPT male hose tail HF1102Z0004 Steel 2 hose tail HF1102Z0014 Aluminium weld-in flush mount C/W flange HF1102Z ½ hose tail HF1102Z0005 Steel weld-on stand pipe HF1102Z mm HF1102Z mm 2 ½ hose tail HF1102Z0015 Aluminium aluminium weld-on flange Aluminium weld-on ring HF1102Z SAE code 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 with Komatsu d with CAT fuel tank HF1102Z with Liebherr 994 / 996 HF1102Z0007 with John Deere fuel tank with CAT D10R / D11R Fuel Inlet 2 NPT male to 2 SAE Code 61 HF1103Z0003 with Hitachi EX with Liebherr 994 / 996 HF1102Z NPT male with CAT 16M 12 bolt flange fuel tank with Hitachi EH with Liebherr 2 SAE Code 61 HF1102Z0011 with Liebherr 2 1/2 NPT female

11 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 Socket 2 NPT HF1011Z0002 Weld in recessed Adaptor 2 NPT female HF1103Z0002 Hydrau-Flo adaptors for use with Komatsu equipment with Komatsu 830e / 930e HF1102Z0003 Hydrau-Flo adaptors for use with CAT equipment with CAT D10R / D11R Fuel tank HF1011Z0001 Designed for use with CAT D10R / D11R Fuel Tank HF1103Z0004 with CAT D10R / D11R Fuel inlet 2 NPT male to 2 SAE Code 61 HF1103Z0003 Hydrau-Flo adaptors for use with John Deere equipment with John Deere Fuel tank Hydrau-Flo adaptors for use with Wiggins equipment 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 HF1012Z Bolt bolt-on float and breather mount 7/8 UNF female thread (lever float) 3/4 BSPT female thread (breather std pipe HF , breather HF0304Z0003) HF1012Z0002 Used with HF1012Z0001 or HF1103Z0001 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 HF1012Z Bolt bolt-on float mount 7/8 UNF female thread HF1012Z0003 Used with HF1012Z0001 or HF1103Z Bolt screw-in float and breather mount 2 male thread HF1103Z0001 NPT BSP Used with HF1012Z0002 or HF1012Z0003 Weld on socket 2 NPT female thread HF1011Z0002 Used with HF1103Z0001

12 12 Hydrau-Flo lines and connectors Pilot Line hose, fittings and accessories 3/8 Pilot Line Nipple reducing 3/8 BSPT M x 1/4 BSPT male HFS Swivel hose tail 3/8 BSPP female x 3/8 hose tail HF Elbow 90 deg female Swivel hose tail 3/8 BSPP female x 3/8 hose tail HF 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 Pilot line check valve 3/8 BSPT female x 3/8 BSPT female HF1204Z0001 Used where 1 x lever float valve is connected to 2 x fuel filling valves. 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. Adaptor 3/8 BSPT female x 1/4 BSPT male HF1204Z0013 Nipple reducing 3/8 BSPT male x 1/2 BSPT male HFS /4 plug Used for plugging unused pilot line port HF1204Z0003 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 HFS Swivel hose tail 1/2 BSPP female x 1/2 hose tail HF Elbow 90 deg female Swivel hose tail 1/2 BSPP female x 1/2 hose tail HF TEE male 1/2 BSPT male HFS Pilot line Magnetic anchor Suit 1/2 hose (20mm to 22mm hose OD) 68kg (150 lbs) pull force Nipple Reducing 9/16 JIC male x 1/4 BSPT male HFS Elbow 90 deg male 9/16 JIC male x 1/4 BSPT male HFS /8 hose crimp Coupling 9/16 JIC male x 3/8 hose crimp HFT /2 push on pilot line hose Single textile braid HF1215Z0002

13 13 3/4 Breather Line Nipple 3/4 BSPT male x 3/4 BSPT male HFS Swivel hose tail 3/4 BSPP female x 3/4 hose tail HF Hose tail 3/4 BSPT male x 3/4 hose tail Elbow 90 deg Female / male 3/4 BSFT female x 3/4 BSPT male Barrel nipple 3/4 BSPT male For mounting HF0304Z003 Rain cap breather HF1014Z0001 Steel air breather 3 micron 3/4 NPT male Nylon air breather 3 micron 3/4 NPT male Built in restriction indicator Replaceable element 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 HF1215Z /4 hose clamp Single textile braid RSC-4347 Hydrau-Flo installantion tools Hydrau-Flo float control valve install tool - side entry Hydrau-Flo fuel filling (blue and black) valve install tool - side entry Hydrau-Flo fuel filling red valve install tool Hydrau-Flo fuel filling (blue and black) valve install tool - top entry Hydrau-Flo Tool kit

14 14 Hydrau-Flo valves dimensions Fuel filling valves (FFV) HF1105Z0006 HF1105Z0007 HF1105Z0002 HF1105Z mmØ (4.9 Ø) 1/4 BSPT Ø100 (3.93 ) 4 NPT 133 (5.2 ) 50mm (1.9 ) 3 NPS 70 (2.75 ) 117 (4.6 ) 104mmØ (4 Ø) HF1105Z0010 HF1105Z0001 Float control valves (FCV) HF1008Z0006 HF1009Z0001 HF1008Z0001 HF1008Z0007

15 15 Lever float control valves HF1007Z0005 HF1007Z0001 HF1007Z0002 HF1007Z0003 FLOAT CLOSED FLOAT OPEN 48 S = T S = SETTING DISTANCE T = THICKNESS OF FUEL TANK MATERIAL Eg = 65mm SET WITH FLOAT CLOSED Anti-Surge Breathers (ASB) 266mm (10.4 ) 129mm (5 ) 122mm (4.8 ) 220mm (8.8 ) 6 (T) 65 (S) 11 HF1007Z NPT 115mm (4.5 ) 2 NPT 115mm (4.5 ) HF1008Z0002 HF1008Z0010

16 Weir Minerals Multiflo is a business unit of Weir Minerals Australia Ltd. Weir Minerals Multiflo 15 Dacmar Road Coolum Beach QLD 4573 Australia T +61 (0) F +61 (0) [email protected] Excellent Minerals Solutions Issued June 2014 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.