Fueltec Models 908 & 919 Mobile Fuel Tank Cleaning Systems

Operation Manual

Fueltec Systems LLC 828-212-1141

www.fueltecsystems.com

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CONTAMINATED DIESEL FUEL

Off road Diesel dyed red

Bacteria & Fungus

Water

Dead bacteria & fungus

The fuel found above the tank bottom water is usually clean and water free. Water being heavier than fuel will be found at fuel tank bottoms. In fuel tanks, bacteria and fungus are commonly found at the fuel/ water interface. These microbes need water to live, without water they will die. They feed on components of the fuel while they float on the water. The dead microbes are heavier than fuel or water and sink to the tank bottom When the fuel is added to a tank where microbes are living, the microbes get mixed with

both the fuel and water and can easily clog filters.

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Microbes found in diesel fuel Virtually all diesel fuel contains some moisture. Additional water accumulates in tanks as atmospheric moisture condenses. Moisture accumulates in diesel tanks as condensate droplets on exposed tank surfaces, as dissolved water in the fuel and as water bottoms beneath the fuel microbes depend on this water for growth. Additionally, microbes depend on the organic and inorganic molecules in diesel fuel for nutrition. Consequently, some species attack the fuel directly, growing at the expense of hydrocarbons and non-hydrocarbon fuel components. The biodegradation of fuel, in support of microbial growth, is a direct impact of contamination. Color, heat of combustion, pour point, cloud point, detergent and anti-corrosive properties change as microbes selectively attack fuel components. Sulfur-containing molecules are metabolized by a series of species, leading ultimately to the production of high concentrations of hydrogen sulfide. In addition to creating new cells, many microbes produce metabolites which promote further attack. Surfactants facilitate the emulsification of fuel, leading to the formation of a cloudy, invert-emulsion layer above the fuel/water interface. Polysaccharide slimes create microenvironments wherein mixed populations (consortia) of bacteria and fungi carry out biodegradation reactions that would be impossible for a single species outside the microenvironment. The slime also serves as a barrier, protecting the microbes from preservatives. A variety of organic acids (primarily 2 - 4 carbon atoms) are also produced as by-products of bacterial and fungal growth.

Diesel Fuel Fungal growth Water

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The System has two modes of operation:

1. Fuel/Water Separation and Filtration mode is used to filter the fuel and sepa-

rate the water froim the fuel.

2. Filtration without Water Separation can be done at a higher flow rate than

with water separation. Generally used to remove particulate in suspension after wa-

ter separation.

INTENDED USE AND OPERATING PRINCIPAL

This System is designed to be used with diesel fuel, heating oil, for re-

moving water, sludge, bacteria, fungus and other contaminants from

fuel tanks.

Models 908 &919 Diesel Mobile Fuel Tank Cleaning Systems

In operation the system pulls fluid from the fuel tank bottom by a vacuum created by the fuel

pump.

A bag type filter is first to remove sludge and solid contaminates from the tank bottom fluid which

may also contain water.

The fuel/water mix leaves the fuel pump under pressure ( do not exceed 40 psi.) and is forced

through a filter/ coalescer where the tiny water droplets are made larger and separate from the

fuel.

The stainless steel/Teflon separator prevent the water droplets from traveling with the fuel. The

water falls to the bottom of the water trap.

A clear sight tube allows you to see the level of the water that has been separated.

With the system running; you can open a valve and send the water to a waste container

and the clean fuel back to the fuel storage tank.

The water level in the sight tube stops rising when all of the water has been

Caution: Not for fluids with a flash point below 100 degrees F.

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WARNING: Read carefully and understand all INSTRUCTIONS before operating. Failure to follow the safety rules and other basic safety precautions may result in serious personal injury, or death. Thank you very much for choosing a FuelTec Systems LLC Product! For future reference, please complete the owner’s record below: Model: _______________ Purchase Date: _______________ Save the receipt, warranty and these instructions. It is important that you read the entire manual to become familiar with this product before you begin using it. This machine is designed for certain applications only. FuelTec Systems cannot be responsible for issues arising from modification. We strongly recommend this machine is not modified and/or used for any application other than that for which it was designed. If you have any questions relative to a particular application, DO NOT use the machine until you have first contacted FuelTec Systems to determine if it can or should be performed on the product. For technical questions please call 1-828-212-1141.

TECHNICAL SPECIFICATIONS Model 919 Diesel Chassis Construction Steel and Aluminum Brite Tread Maximum lift 15 feet primed Working pressure fuel max. 40 PSI Maximum Flow rate 1,140 Gallons per hour * Water Trap two (2) Gallons US Power 115/230V 1PH 60Hz 1-1/2HP Width: 32” Depth: 47” Overall Height 60” Pump positive displacement, with internal bypass Inlets/Outlets 1” Cam-Loc w/ Ball Valves Hose Supply& Return 1” X 12’ each Vacuum Gauge 2” liquid filled Sludge Filters 24” Fueltec Bag Water Coalescer micro-glass (military type) Water Separator Teflon hydrophobic Wheels 13” flat free

TECHNICAL SPECIFICATIONS Model 908 Diesel Chassis Construction Steel and Aluminum Brite Tread Maximum lift 15 feet primed Working pressure fuel max. 40 PSI Maximum Flow rate 480 Gallons per hour * Water Trap two (2) Gallons US Power 115/230V 1PH 60Hz 1/2HP Width: 32” Depth: 47” Overall Height 50” Pump positive displacement, with internal bypass Inlets/Outlets 1” Cam-Loc w/ Ball Valves Hose Supply& Return 1” X 12’ each Vacuum Gauge 2” liquid filled Sludge Filters 24” Fueltec Bag Water Coalescer micro-glass (military type) Water Separator Teflon hydrophobic Wheels 13” flat free

* Flow rates may vary with filter type and condition, length and size of hoses, and size and shape of fluid pickup and return tubes.

General Safety Regulations WARNING: Maximum fuel pressure setting not to exceed forty (40) psi. WARNING: Read and understand all instructions. Failure to follow all instructions listed below may result in explosion, fire ,serious injury, and/or death. WARNING: The warnings, cautions, and instructions discussed in this instruction manual cannot cover all possible conditions or situations that could occur. It must be understood by the operator that common sense and caution are factors which cannot be built into this product, but must be supplied by the operator.

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SAVE THESE INSTRUCTIONS WORK AREA

Mark work area with orange colored safety cones

placed in a radius of at least twenty five (25’) feet from

fuel tank cleaning equipment, fuel containers, and fuel

tank openings.

Place Flammable Liquid Warning Signs within work ar-

ea

Keep work area clean, free of clutter and well lit. Clut-

tered and dark work areas can cause accidents.

Keep children and bystanders away while operating this

system. Distractions can cause you to lose control, so visi-

tors should remain at a safe distance of at least twenty five

(25’) feet from the work area.

Be aware of all power lines, electrical circuits, water pipes and other me-

chanical hazards in your work area, particularly those hazards below the work sur-

face hidden from the operator’s view that may be unintentionally contacted and

may cause personal harm or property damage.

Be alert of your surroundings. Using your system in confined work areas may

put you dangerously close to unsafe conditions.

Keep electric cord plug ends at least twenty five feet (25’) feet from fuel tank

cleaning equipment, fuel containers, and fuel tank openings.

PERSONAL SAFETY

Stay alert, watch what you are doing and use common sense when operating

or maintaining the system. Do not install or maintain the system while you are tired

or under the influence of drugs, alcohol or medication. A moment of inattention

while installing or maintaining the system may result in serious personal injury or

death.

Dress properly while operating this system. Do not expose bare skin or eyes

to fuels. Prolonged contact with fuel can damage the skin.

Use safety apparel and equipment. Use safety goggles or safety glasses with side shields which comply with current national standards, or when needed, a face shield. This applies to all persons in the work area. Also use non-skid safety shoes,

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Air Bleed Valve

Filtered only fuel & direct pump transfer port

Inlet valve Sludge filter inlet port Vacuum gauge Valve settings Sludge filter housing Contaminate drain port

Coalescer Housing

Separated &Filtered fuel return port

Separated Water

Sight Tube

Drip Pan

Pressure Gauge

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Fuel Pump

Pump off/on switch Pump motor circuit breaker reset Pump pressure relief valve

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Sludge Filter inlet Port

Pressure Gauge

Vacuum Gauge

Fuel Transfer Outlet

Separated Water Drain Valve

Water Drain Port

Remove swing bolts from housing cover

then prime system with two (2) gallons

of clean fuel before starting the pump.

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1. Open air bleed valve 6., close

sludge filter inlet valve 1.

2. Run fuel pump for 10 seconds.

3. Remove Filter Cover

4. Remove Spring

5. Remove and replace Soiled Filter

Bag after each use.

6. Dispose of used filter bag in an ap-

proved manner according to Gov-

ernment Regulations.

7. Insert New Filter Bag into Housing.

8. Seat Bag Flange on housing ledge.

9. Insert Spring

10. Install Filter Housing Cover

11. Tighten cover nuts HAND TIGHT

ONLY!!

BAG FILTER REPLACEMENT

PRIMARY FILTER SELECTION

Gasoline: 1 micron primary filter (1M24)

Kerosene: 1 micron primary filter (1M24)

Jet Fuel: 1 micron primary filter (1M24)

No. 2 Diesel: 5 or 10 micron primary

filters: (5M24 or 10M24)

Note: Fuel tanks with heavy sludge build

up will require multiple bag changes.

13. Close air bleed valve 6. and open sludge filter inlet valve 1. 14. Resume operation.

Over-tightening eye nuts may

cause filter housing damage

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Coalescer and Separator Replacement

1. Stop fuel pump.

2. Remove coalescer/ filter cover

3. Loosen 3/8” hex separator retaining nut.

4. Remove Separator cartridge. (coalescer may come with it)

5. Apply Vaseline to new coalescer o-rings and insert coalescer into separator.

6. Insert coalescer and separator into housing until 3/8” tie-rod protrudes

through top of separator.

7. Install 3/8” o-ring, washer, and hex nut onto tie-rod and tighten to 5 ft/lbs.

8. Install housing cover, tighten eye nuts hand tight only (do not use tools) and

resume operation.

Over-tightening eye nuts may cause filter housing damage

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Maximum Water Separation & Filtering Connect Return to Tank Hose to Port 2.

Connect Pickup Tube Hose to Filter Port 1. Open Valves 1. & 2. Close Air Bleed Valve 4. Set 3-way valve as shown below

Bulk Fuel Transfer & Fast Filter Without Water Sepa-ration Connect Pickup Tube Hose to Port 1. Connect Return Hose to Port 3. Open Valves 1. Close Valve 2. Fluid is now bypassing the water separator. Note 3-way Valve position Caution: Do not use this option if water is found in the fuel tank as the fuel and water may become emulsified beyond separation.

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Start Up System to Service a Fuel Tank

1. Close air bleed valve. page 6, contaminant drain valve. page 6,

2. Install Bag Filter as shown on page 9.

3. Prime pump by filling sludge filter housing with two gallons of product. If

pump is not primed pump seal damage may occur.

4. Attach fluid supply hose to sludge filter port.

5. Attach fluid return hose to separated fuel return port .

6. Attach pickup supply & return tubes & or manifold to hoses.

7. Insert Manifold into fuel storage tank opening and connect hose.

8. Insert fluid supply pickup tube into the tank manifold to a point just under

the fluid level until the coalescer housing is filled.

9. Open Sludge filter valve full open.

10. Open Separated Fuel Return Valve

11. Switch Fuel Pump On; Pump will start.

12. Fluid should be seen in sight tube in 20 seconds.

13. Cycle pump until the system is full of clean fuel.

14. Move the fluid pickup tube to the lowest portion of the fuel tank to remove the

contaminates only after steps 1 thru 13 have been completed.

15. Watch sight tube for the presents of water. (water on bottom fuel on top)

16. When water level reaches six (12”) inches; open contaminant drain valve and

place drain hose into waste container.

17. Control water level in sight tube with drain valve & return to tank valve (This

allows you to send the separated water to a waste container and the cleaned

fuel back to the tank without any loss of fuel)

21. The water level in the sight tube stops rising when all of the water has been

vacuumed and separated from the fuel storage tank.

High water level Low water level Drain valve

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23. Observe Vacuum Gauge. two minutes after fluid appears in sight tube; The

initial Vacuum reading will be determined by the elevation of the supply port

relative to the elevation of the fluid level in the tank being serviced. Make note of

this first gauge reading. As the bag filter accumulates debris the vacuum reading

will increase. When the gauge reading has increased 8” Hg. above the initial

reading; the filter bag needs to be changed.

Observe Vacuum Gauge on primary

filter housing.

24. Observe the Pressure Gauge. When the gauge reads 22 PSI, the coalescer

filter needs changing.

Observe the Pressure Gauge on the bot-tom of the coalescer/ water separator housing

Fueltec Systems, LLC

3821 N Main Street Granite Falls, NC 28630

www.fueltecsystems.com

(828) 212-1141 © 2014 RLENZ

100% Made in USA

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Typical Fuel Tank De-Watering and Filtration: Underground and Above ground Fuel Storage Tanks:

Remove cap or fitting to access tank bottom.

Test for high bulk water level with Water Gauging Paste or Sampler.

Set the system Mode to bulk transfer to remove all but the last two inches of bulk

water from the tank.

Insert supply and return manifold into tank opening and connect system hoses.

Pump out bulk water.

Set the system Mode to Separate Water.

Operate the system and observe the separated water level in the water trap.

Empty the water trap as the system is running; stop operation when water is no

longer accumulating in the trap.

If suspended particulates are observed in the sight tube after water has been re-

moved; Set the system Mode to Filtration.

Use 5-10 micron filters for diesel and 1-5 micron filters for gasoline & ethanol

Operate system until the fuel is clear.

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TYPE “D” CAM-LOCK INCLUDED WITH SYSTEM

FUELTEC’S FUEL SUCTION HOSE

FLUID PICKUP TUBE MADE IN FIELD TO REACH

FUEL STORAGE TANK BOTTOM.

TUBE CAN BE MADE FROM STEEL PIPE, ALUMINUM,

STAINLESS STEEL, PVC, NYLON-6, POLYURETHANE,

OR ANY MATERIAL IMPERVIOUS TO THE FUEL

THAT YOU ARE IN CONTACT WITH.

CUT TUBE BOTTOM AT 45 DEGREES

FUEL TANK BOTTOM

ATTACH PICKUP TUBE TO CAM-LOCK “D” WITH A

STREET ELBOW FITTING

FLUID PICKUP TUBE BUILDING FOR FUELTEC’S MOBILE SYSTEMS

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1” SUCTION HOSE

RETURN TO TANK HOSE

FUEL TANK BOTTOM

CLEAN DRY FUEL RETURNING TO

TANK THROUGH SHORT PIPE

SUCTION INTAKE ON

TANK BOTTOM

1” SUCTION TUBE

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TANK CLEANING USING THE FUELTEC M-2 SUPPLY & RETURN MANIFOLD

ALLOWING SUPPLY AND RETURN THROUGH ONE 2” TANK FITTING TYPICAL

ON GENERATOR BASE TANKS

FUEL TANK BOTTOM

SUCTION HOSE

RETURN TO TANK HOSE

CLEAN DRY FUEL RETURNING

TO TANK THROUGH MANI-

SUCTION INTAKE ON

TANK BOTTOM

1/2 INCH PIPE FUEL

PICKUP SUCTION

TUBE

For use with models 908 electric, 950AW , & 955SS

when removing water from a fuel tank.

Use at lowest flow rate possible when separating

water to reduce the velocity which will minimize

emulsification with water and diesel. After water

has been removed you can use max. flow rate.

Model 919 flow rate of 19 GPM fixed will produce

a velocity in the 1/2” pipe suction tube of 21 feet

per second, which is high. Use a 1” suction pipe

which will produce a velocity of 7.4 feet per second.