MI320/01 EN

FUEL AUTOMATIC
LOADING KIT

Instruction Manual

Séries ENERGY PRIME

Contents
1. Introduction ......................................................................................................................................................................................... 3
2. Intended use ....................................................................................................................................................................................... 3
3. Device description ............................................................................................................................................................................... 3
3.1. Standard loading kit ....................................................................................................................................................................... 3
3.2. Other types of loading (only supplied on specific request) ............................................................................................................ 5
4. Operating logic .................................................................................................................................................................................... 6
5. Hydraulic connections ......................................................................................................................................................................... 7
5.1. Hydraulic connection of the kit to the system ................................................................................................................................. 7
5.2. Integrated or return tank vent ......................................................................................................................................................... 7
6. Pump priming ...................................................................................................................................................................................... 8
7. Operating checks ................................................................................................................................................................................ 9
8. Maintenance ....................................................................................................................................................................................... 9
9. Disposal .............................................................................................................................................................................................. 9

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 1. Introduction
This manual concerns the use and maintenance of the fuel automatic loading kit assembled inside a “Efaflu Generating Set” (here in
after referred to as Genset).

This manual, along with the genset, engine and alternator manuals and other documents delivered with the unit, are an integral part of
the “Efaflu Generating Set”. Please note that should the instructions in the manuals differ, those to be complied with and applied must
be the safest and strictest.

Before beginning any type of operation on the loading kit, we advise you to carefully read this manual and the other supplied documents
and to follow the safety standards and the standards for correct generating set use and maintenance. Should any doubts arise while
reading the manual or using the unit, please contact a Visa technician. The information contained herein is correct at the time of printing
but can be changed without prior notice or notification, in line with our objectives of continuous product development and improvement.

2. Intended use
This fuel loading kit is an extra item and, when requested, it is already connected to machines that are built by Efaflu and managed
by COMAP AMF25, or other controllers.
This kit is suitable for loading return tanks located on machines, loaded by drawing fuel from cisterns that are underground or, in any
case, at a level lower than the return tank itself.
The electric pump is self-priming; during start-up, with the suction pipe emptied and the pump wet with the fluid, the electric pump can
extract liquid with a maximum height difference of 2m. Priming can last up to a minute. Once the liquid has been primed, the pump can
also operate with greater height differences. However, you are required to:
 install a foot valve to prevent the suction pipe from emptying;
 never exceed height differences over 3m.
In every case where this kit has to operate with greater height differences, or in conditions other than those recommended (see also
Chapter 7 - Hydraulic Connections), consult EFAFLU.
This kit must be used exclusively with Fuel for traction in compliance with EN590.
Any other use is not approved by EFAFLU.
Using the kit with any other type of fuel, including mineral or vegetable oil, is prohibited.
Using the unit in environments that are classified according to the directive 99/92/EC (environments with risk of explosion, etc.) is not
allowed.

3. Device description
3.1. Standard loading kit
Below are the main components that make up the automatic loading kit, referring to Fig.1.

Part. DESCRIPTION
1 220V single-phase electric pump
2 Semi rotary hand pump
3 ½” gate valve
4 ¾” gate valve
5 ¾” connection for pipes from the cistern (intake)
6 Pipe going to the unit (supply)

The loading kit can have different configurations according to the machine and installation, as illustrated in Fig. 2.

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4 6

2 1

4 5

Fig. 1 Example of a loading kit on an open machine version

2
4

3
1

Fig. 3 Another example of a loading kit configuration

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 Fig. 2 Example of a loading kit on a machine with a canopy

3.2. Other types of loading (only supplied on specific request)

Loading kit with electric pump only (see example in Fig. 4).
The instructions for a standard loading kit apply, except with regard to all operations regarding the hand pump, which is not present.

Fig. 4 Electric pump only

Kit with a double electric pump and hand pump (see Fig. 5).
The components in this loading kit and the operating logic differ from a standard loading kit. Consequently, the instructions in this
manual are not valid for this type of loading.
For information regarding (field of use, operating logic, hydraulic and electric connection instructions, etc.), consult EFAFLU.

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 Fig. 5 Loading kit with double electric pump

4. Operating logic
Read this manual carefully and consult the machine wiring diagrams for loading kit activation and operating methods.

In the event of a system error, the junction box cuts power to the electric pump, thus blocking loading. The junction box creates an error
message accompanied by a visual and/or acoustic signal, in addition to giving a signal that can be sent remotely.
In the event of an error or no power supply to the electric pump, the hand pump, which is connected in parallel to the electric pump,
allows the tank to still be loaded.
To go into this mode:
1. close the ½” gate valve (part. 3 of Fig. 1) turning it until it is in a horizontal position (see Fig. 6 - loading via hand pump);
2. open both ¾” gate valves (part. 4 of Fig. 1) by turning them until they are in a vertical position;
3. vigorously activate the hand pump lever.

Loading via electric pump Loading via hand pump

Fig 6

Upon completion of the operation, put the system back into automatic mode, remembering to return the gate valve to its
initial position (see Fig. 1).

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 5. Hydraulic connections
5.1. Hydraulic connection of the kit to the system
Do not start-up or perform maintenance, repairs or alterations without adequate training. All the operations must be performed in
compliance with the safety standards and by qualified operators.

Connection of the fuel system to the machine loading couplings must be planned and carried out solely by qualified
technicians. Errors when installing or using the machine can seriously damage the user system, the machine itself or injure
those involved. Once installation is complete, the person responsible for the installation must leave the end customer a
declaration certifying operation in compliance with all the regulations in force in the place of use.

There may be dangerous voltages inside the electric pump and solenoid valve. Do not start-up or perform maintenance,
repairs or alterations without specific knowledge.

Before any installation, commissioning, maintenance or inspection operations, disconnect the loading kit from any source of
power supply.

To connect the machine supplied with a loading kit and fuel storage system, proceed as follows:

1. Identify the position of the couplings on the machine, to which the supply and overflow pipes can be connected. The position of
these couplings may vary depending on the model of the machine purchased. Some photos are reported in the photos below. It is
necessary to use pipes that are suitable for the aim, possibly rigid and in metal (steel or copper), for the hydraulic connections. Be
particularly careful to clean shavings from pipe threading.

2. Connect the dip tube in the cistern (see cistern documents) to the 1” “IN” coupling located on the canopy of the genset in the case
of a silenced machine, or directly onto the ¾” connection of the loading kit (part. 5 of figure 1) in the case of a machine without a
canopy. In this pipe section on the edge of the cistern, the best working standard requires inserting a jerk handle valve (not
included in standard supply). For sections shorter than 5/6 metres, we recommend using 1" diameter pipes.

3. Connect the 1”½ "OUT" connection on the genset to the overflow coupling on the cistern (see cistern documents). For sections
shorter than 5/6 metres, we recommend using 1"½ diameter pipes for the overflow line.

IN OUT

Fig. 7: Examples of the mounting method of loading couplings

5.2. Integrated or return tank vent

The fuel supply system must be equipped with a vent.

Incorrect positioning of the breather pipes can cause serious damage to the machine, the user system and the personnel
involved.

The vent for the return tank or the machine tank must be done through the overflow pipe (refer to Fig. 8):
1. find vent E on tank A: it can be identified by a specific tag (see Fig.9).
2. remove (use the sealing plug) vent E;
3. ensure that any direct filler caps on tank A have been sealed or replaced with sealing plugs;
4. ensure that vent F in cistern C is taken to a higher level than the one inside the fuel supply system (supply and return lines
included);

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 5. ensure that there are no siphons as shown in Fig.8 detail B. If there are siphons, they will not allow venting. Line 2, also used
as a vent, must be given a constant upward incline towards the highest point of tank C.

A Machine or return tank F Specific vent on main storage tank C

B Example of siphon created on a return line H Vent height
C Main storage tank Line 1 Supply pipe
D On board loading kit Line 2 Overflow pipe
E Specific vent on tank A
Fig 8

Fig 9

6. Pump priming
Despite being self-priming, at the first start-up or after long pauses, the electric pump may not have the capacity to expel the air inside
the circuit and therefore to prime the fuel.

To wet the electric pump impeller and make it easier to prime the pump, proceed as follows (see Fig. 10):
1. Ensure that the suction and supply gate valves of the hand pump (part. 6-7 of Fig. 1) are closed;
2. loosen the supply pipe clamp of the hand pump and disconnect the pipe;
3. slowly pour the fuel in order to let air escape and enable the fuel to pass through the suction pipe;
4. reconnect the pipe to the rubber holder, restore the initial position of the gate valves (see Fig. 1) and activate the electric
pump.

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 Fig. 10

As an alternative to filling the circuit manually, it is possible to trigger the electric pump by using the hand pump. Proceed as follows:
1. ensure that the hand pump supply pipe is connected;
2. close the electric pump supply gate valve (part 3 of Fig. 1) and open the one on the hand pump suction and supply (part. 4 of
Fig. 1);
3. activate the hand pump until fuel starts coming out of the supply pipe;
4. close the hand pump suction and supply (part. 4 of Fig. 1) and open the electric pump suction (part 3 of Fig. 1);
5. restore the power supply and activate the electric pump.

7. Operating checks
Before starting the circuit:
 ensure that the cistern dip tube is equipped with a foot valve: the vertical drawing (suction) tube must never be empty;
 ensure that the maximum height difference between the electric pump and the lowest part of the dip tube does not exceed the
limit specified in chapter 2;
 ensure that the transfer kit has correctly set spigots (see chapter 4).

Once the system has been connected and the electric pump has been activated, carefully ensure that:
 there are no leaks during loading;
 the breather pipe is free and functional;
 the pump capacity is not excessive: depending on the line load leaks, the size of the vent and the size of the return tank, it
may be necessary to install another regulator spigot on the supply line.

8. Maintenance
There may be dangerous voltages inside the electric pump and solenoid valve. Do not start-up or perform maintenance,
repairs or alterations without specific knowledge.

Before any installation, commissioning, maintenance or inspection operations, disconnect the loading kit from any source of
power.

Close the gate valve so that the system is isolated.

Once the loading kit is isolated:

 check the pipe couplings weekly to make sure they are not loosened to avoid possible leakage;
 check the pump body monthly and keep it clean from any impurities (also see the electric pump manual);
 check the electric pump filter monthly and keep it clean, as well as any other installed filters (also see the electric pump
manual);
 check the power cables monthly to make sure they are in good condition.

In addition, check the loading kit to make sure it functions properly in general in conjunction with periodic machine testing (see genset
manual).

9. Disposal
In the event of machine maintenance or demolition, properly dispose of polluted parts.
At the end of its use or in the event of demolition, the device or its parts must be disposed of according to the applicable legislative
requirements in the destination country.

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