Weir HYDRAU-FLO HF1105Z0001 User manual

Weir Minerals Multiflo®
Safety Solutions for Liquid Filling
HYDRAU-FLO®FUEL FILLING SYSTEM
Installation, Operation and Maintenance Manual
Document Number:
Revision: 0
Issue Date: 23 February 2015
CONTROLLED DOCUMENT
Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved .
Installation, Operation and Maintenance Manual
Copyright © 2015, Weir Minerals Australia Ltd trading as Weir Minerals Multiflo®. All rights reserved.
MULTIFLO, VACTRONIC and HYDRAU-FLO are registered trademarks of Weir Minerals Australia Ltd. This
document contains information which is confidential to Weir Minerals Australia Ltd. It should not be disclosed
in whole or in part to parties other than the recipient without the express written permission of Weir Minerals
Australia Ltd authorized personnel.

Weir Minerals Multiflo®
Safety Solutions for Liquid Filling
HYDRAU-FLO®FUEL FILLING SYSTEM
Installation, Operation and Maintenance Manual
Document Number:
Revision: 0
Issue Date: 23 February 2015
CONTROLLED DOCUMENT
Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved .
HYDRAU-FLO®COMPONETS ARE ONLY
RATED FOR THEIR INTENDED USE.

Weir Minerals Multiflo®
Safety Solutions for Liquid Filling
HYDRAU-FLO®FUEL FILLING SYSTEM
Installation, Operation and Maintenance Manual
Document Number:
Revision: 0
Issue Date: 23 February 2015
CONTROLLED DOCUMENT
Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved .
Revision History
Revision
Description
Reviewed
Authorised
Date

Weir Minerals Multiflo®
Safety Solutions for Liquid Filling
HYDRAU-FLO®FUEL FILLING SYSTEM
Installation, Operation and Maintenance Manual
Document Number:
Revision: 0
Issue Date: 23 February 2015
CONTROLLED DOCUMENT
Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved .
Contact Details
Head Office
Equipment Placement Sales and Services
170 Kewdale Road
Kewdale WA 6105
Ph: 08 9479 4988
Fax: [phone]
Email: [email protected]
PT Weir Minerals Multiflo®
Jl Mulawarman No 29A RT
003 Batakan Kecil Kelurahan Manggar
Balikpapan 76117
East Kalimantan
Indonesia
Ph: 62 542 746098
Fax: [phone]
Banjarbaru Branch Office
Jl. Ahmad Yani Km 33,6 Ruko
No. 04 RT.
003 RW.001 Kelurahan
Loktabat Selatan
Banjarbaru 70712
South Kalimantan
Indonesia
Ph: 62 511 4773027
62 511 4772357
Fax: [phone]

HYDRAU-FLO®
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Table of Contents
Contact Details..................................................................................................................................................................ii
Australia.............................................................................................................................................................................ii
Indonesia ...........................................................................................................................................................................ii
Table of Contents...........................................................................................................................................................1-3
List of Figures ................................................................................................................................................................1-6
List of Tables..................................................................................................................................................................1-7
1Introduction..........................................................................................................................................................1-1
1.1 Disclaimer ........................................................................................................................................................1-1
1.2 Copyright..........................................................................................................................................................1-1
1.3 Warranty...........................................................................................................................................................1-1
1.4 Intended Audience...........................................................................................................................................1-1
2Safety....................................................................................................................................................................2-2
2.1 Safety Symbols................................................................................................................................................2-3
2.2 General Safety.................................................................................................................................................2-5
2.3 Qualified Workers ............................................................................................................................................2-5
2.4 Safe Working....................................................................................................................................................2-5
2.5 Safety Equipment.............................................................................................................................................2-5
2.6 Risks ................................................................................................................................................................2-5
2.7 Operating Conditions .......................................................................................................................................2-6
2.8 Material Safety Data Sheets............................................................................................................................2-6
2.9 Intended Use of the Product............................................................................................................................2-6
2.10 Unintended Use of the Product........................................................................................................................2-6
2.11 Warranty...........................................................................................................................................................2-7
3Description...........................................................................................................................................................3-9
3.1 Hydrau-Flo®Fuel Filling Valve.........................................................................................................................3-9
3.2 Working Principle.............................................................................................................................................3-9
3.3 Hydrau-Flo®Configurations ...........................................................................................................................3-11
3.3.1 Hydrau-Flo®Range of Fuel Fillings Valves............................................................................................3-11
3.3.2 Hydrau-Flo®Float Control Valves..........................................................................................................3-13
3.3.3 Hydrau-Flo®Anti-Surge Breathers.........................................................................................................3-14
3.3.4 Hydrau-Flo® Lever Float Control Valve..................................................................................................3-15
3.4 Hydrau-Flo® Hardware ...................................................................................................................................3-16
3.4.1 Hydrau-Flo®Black Fuel Filling Valve Adaptors......................................................................................3-16
3.4.2 Hydrau-Flo®Blue, Gold and Red Fuel Filling Valve Adaptors...............................................................3-17
3.4.3 Pilot Line Hose Fittings and Accessories...............................................................................................3-18
3.4.4 Breather Line Connectors......................................................................................................................3-19
3.4.5 Exhaust Line Float Control Valves and Breather Hose, Fittings and Accessories................................3-19
3.4.6 Pilot Line ................................................................................................................................................3-20
3.5 Optional Features ..........................................................................................................................................3-21
3.5.1 Internal Pilot Lines .................................................................................................................................3-21

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3.5.2 Anchoring Pilot Lines .............................................................................................................................3-21
3.5.3 Vertical Float Extensions .......................................................................................................................3-22
3.5.4 Lever Float (Fixed) Connections............................................................................................................3-23
3.5.5 Hydrau-Flo®Applications.......................................................................................................................3-24
3.6 Hydrau-Flo®Valves Dimensions....................................................................................................................3-24
4Installation..........................................................................................................................................................4-25
4.1 Pre-Installation...............................................................................................................................................4-25
4.2 Installation Tool Kit.........................................................................................................................................4-25
4.3 Installation Procedure –To suit General Installation.....................................................................................4-26
4.4 Installation Procedure –To suit CAT D10R/D11R Dozers............................................................................4-27
4.5 Installation Procedure - To suit CAT 16H Grader..........................................................................................4-28
4.6 Additional Information on Installation.............................................................................................................4-29
4.6.1 General Arrangement ............................................................................................................................4-29
4.6.2 Multiple Filling Valves with Single Lever Float Valve.............................................................................4-30
4.6.3 Multiple Filling Valves with Single Vertical Float Valve..........................................................................4-31
4.6.4 Check Valve Arrangement.....................................................................................................................4-32
4.6.5 Lever Float Height Adjustment...............................................................................................................4-32
5Commissioning..................................................................................................................................................5-33
6Operation............................................................................................................................................................6-34
6.1 Fuel Filling......................................................................................................................................................6-34
6.2 Flow Specification..........................................................................................................................................6-34
6.3 Fuel Filling of Dual Tanks ..............................................................................................................................6-34
6.4 Multiple Filling Valves Flow Rating ................................................................................................................6-34
6.5 Suitable Mediums ..........................................................................................................................................6-35
6.6 Fuel Consumption..........................................................................................................................................6-35
6.7 Fuel Reticulation ............................................................................................................................................6-35
6.8 Float Control...................................................................................................................................................6-35
7Maintenance.......................................................................................................................................................7-36
7.1 Maintenance Instructions...............................................................................................................................7-36
7.2 Troubleshooting Guide...................................................................................................................................7-37
8Appendices ........................................................................................................................................................8-38
8.1 Commissioning Checklist...............................................................................................................................8-38
8.2 Maintenance Checklist...................................................................................................................................8-39
8.3 Black Valve with Hydrau Flo®Receiver.........................................................................................................8-40
8.4 Red Valve in Adapter with Hydrau Flo®Receiver..........................................................................................8-41
8.5 Blue Valve with Hydrau Flo®Receiver...........................................................................................................8-42
8.6 Single Receiver and Single Vertical Float (Mobile) General Arrangement....................................................8-43
8.7 Single Receiver and Single Lever Float (Stationary) General Arrangement.................................................8-44
8.8 Lever Float Dimension Drawing.....................................................................................................................8-45
8.9 Fuel Lever Float Settings...............................................................................................................................8-46
8.10 Vertical Float Drawing....................................................................................................................................8-47
8.11 Float Control Valve Drawing (Catch Tank Option).........................................................................................8-48

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8.12 Catch Tank Option with Breather Option Drawing.........................................................................................8-49
8.13 Vertical Float Shutoff Point Drawing..............................................................................................................8-50
8.14 Vertical Float Shutoff Point Drawing..............................................................................................................8-51
8.15 Check Valve Selection Drawing.....................................................................................................................8-52
8.16 Black Valve Drawing......................................................................................................................................8-53
8.17 Red Valve Drawing ........................................................................................................................................8-54
8.18 Blue Filter Valve Drawing...............................................................................................................................8-55
8.19 Gold Valve Drawing.......................................................................................................................................8-56
8.20 Environmental Exposure Certificate ..............................................................................................................8-57
8.21 Explosive Atmospheres Certification .............................................................................................................8-58
8.22 Hydrau-Flo®Parts List ...................................................................................................................................8-59
8.23 Hydrau-Flo®Deliverables...............................................................................................................................8-61

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List of Figures
Figure 3-1: Working Principle of a Mobile and Stationary Fuel Filling Set-up.................................................................3-9
Figure 3-2: Operation of Hydrau-Flo®Fuel Filling System (Vertical Float Not Shown) ................................................3-10
Figure 3-3: Roll Over Protection ....................................................................................................................................3-14
Figure 3-4: Hydrau-Flo®Pilot Line Arrangement for Vertical and Lever Float Control Valves ......................................3-20
Figure 3-5: Converting External Pilot Line to an Internal Line.......................................................................................3-21
Figure 3-6: Hydrau-Flo®Pilot Line Magnet Anchor........................................................................................................3-21
Figure 3-7: Barrel Extensions (300mm and 150mm Extensions Shown)......................................................................3-22
Figure 3-8: Trickle Feed System with Two Floats .........................................................................................................3-24
Figure 4-1: Multiple Filling Valves with Single Lever Float and Check Valve................................................................4-30
Figure 4-2: Multiple Filling Valves with Single Vertical Float and Check Valve.............................................................4-31
Figure 4-3: Check Valve Arrangement ..........................................................................................................................4-32

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List of Tables
Table 2-1: Safety Colours................................................................................................................................................2-3
Table 2-2: Safety Symbols...............................................................................................................................................2-4
Table 3-1: Fuel Filling Valves ........................................................................................................................................3-11
Table 3-2: Float Control Valves .....................................................................................................................................3-13
Table 3-3: Anti-Surge Breathers....................................................................................................................................3-14
Table 3-4: Lever Float Control Valve.............................................................................................................................3-15
Table 3-5: Black Valve Adaptors ...................................................................................................................................3-16
Table 3-6: Black, Gold and Red Valve Adaptors...........................................................................................................3-17
Table 3-7: Pilot Line Hose Fittings and Accessories .....................................................................................................3-18
Table 3-8: Breather Line Connectors.............................................................................................................................3-19
Table 3-9: Exhaust Line Accessories ............................................................................................................................3-19
Table 3-10: Lever Float Extensions...............................................................................................................................3-23
Table 4-1: Installation Tool Kit .......................................................................................................................................4-25
Table 4-2: General Arrangement for Single Receiver and Single Valve .......................................................................4-29
Table 7-1: Troubleshooting Guide .................................................................................................................................7-37

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HYDRAU-FLO®Valves
Introduction
1 Introduction
The purpose of this Manual is to advise and instruct installers, and operators of Weir Minerals Hydrau-Flo®Fuel Filling
System regarding the recommended installation, operation and maintenance of the equipment. The following
information will aid you in the installation, operation and maintenance of your new Weir Minerals Hydrau-Flo®Fuel
Filling System. To ensure long life and trouble-free operation, it is imperative that the instructions contained in these
manuals are read understood and carried out by all users of this product.
The Weir Minerals Hydrau-Flo®Fuel Filling System is of robust construction and is used to prevent build-up of pressure
and overfilling in the fuel tank. It has been designed to be used in conjunction with the existing “fast fill” systems and
also the traditional splash filling systems. The Hydrau-Flo®Valve Kits are manufactured to suit a wide range of
industrial applications in the mining, oil and gas, transport, construction and maritime sectors. Configurations are
designed for individual equipment needs.
Please check our website www.weirminerals.com/hydrau-flo or search YouTube®for “Hydrau-Flo®“to view the
promotional animation video on how the system works.
1.1 Disclaimer
Despite of the care taken to compile all information and illustration in this document, neither the author nor the
publisher can be held liable for any consequential damages resulting from possible errors in this publication.
The English language was used to write the original manual. Any versions in other languages are translation of the
original manual instructions. These translated versions may contain information that differs from the original due to
interpretation of the content and meaning of the original text. In the case of such discrepancies, the original English
language instructions will be considered the sole authentic source for the purpose of determining the content and
meaning of the text.
Weir Minerals Multiflo®reserves the right to make changes to technical and design specifications at the any time
without prior notice.
1.2 Copyright
Weir Minerals Multiflo®Pty Ltd 2015
This document is subject to copyright. Use or copying of this document in whole or part without the written permission
of Weir Minerals Multiflo®constitutes an infringement of copyright.
1.3 Warranty
All Hydrau-Flo®Fuel Filling Valve components are covered with a 36 month manufacturer warranty. It is not
recommended that unauthorised personnel service the Hydrau-Flo® components and may result a void of warranty. For
information regarding servicing or warranty claims, please contact Weir Minerals Multiflo® on the contact details
provided at the beginning of this manual.
1.4 Intended Audience
This manual is intended for:
Personnel who have a relevant basic level of trade/professional competency.
CAUTION
PERSONNEL INJURY
The Hydrau-Flo®components must be installed and operated by personnel who are trained and have
sufficient knowledge about the hazards that may occur during operations.