Axi MTC-1000 Parts list manual

5400 Division Dr. | Fort Myers, FL 33905
239 690-9589 | Toll Free 877-425-4239 | FAX [phone]
www.AXI-International.com
MTC
MTC-1000 Instruction,
Operating, & Maintenance
Manual
MOBILE FUEL POLISHING SYSTEM
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Table of Contents
Table of Contents ................................................................................................................................................................ 2!
General Overview ................................................................................................................................................................ 3!
MTC-1000 Specifications ................................................................................................................................................... 3!
System Components ........................................................................................................................................................... 4!
Control and Safety Devices................................................................................................................................................ 4!
Pump/Motor........................................................................................................................................................................ 4!
Primary Filter/Water Separator .......................................................................................................................................... 4!
Fuel Conditioner................................................................................................................................................................. 4!
Fine Filter ........................................................................................................................................................................... 4!
Plumbing ............................................................................................................................................................................ 4!
System Operation ................................................................................................................................................................ 5!
Setup Procedures .............................................................................................................................................................. 5!
Phase 1 .............................................................................................................................................................................. 5!
Phase 2 .............................................................................................................................................................................. 6!
Phase 3 .............................................................................................................................................................................. 6!
Draining and Storing the System ....................................................................................................................................... 6!
Primary Inspection .............................................................................................................................................................. 7!
Checklist............................................................................................................................................................................. 7!
Priming the System ............................................................................................................................................................. 8!
Priming Procedure ............................................................................................................................................................. 8!
Maintenance ......................................................................................................................................................................... 9!
Preventative Maintenance.................................................................................................................................................. 9!
Servicing the Pump ............................................................................................................................................................ 9!
Servicing the Primary Filter/Water Separator..................................................................................................................... 9!
Servicing the Fine Filter ................................................................................................................................................... 10!
Replacement Filter Chart ................................................................................................................................................. 10!
Troubleshooting ................................................................................................................................................................ 11!
Symptom Troubleshooting Guide..................................................................................................................................... 11!
AXI International Limited Warranty.................................................................................................................................. 12!
Warranty Claim Procedure ............................................................................................................................................... 13!
Technical Assistance and Ordering................................................................................................................................. 14!
Replacement Filter Elements ........................................................................................................................................... 14!
System Identification ........................................................................................................................................................ 14!

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General Overview
MTC-1000 Specifications
Nominal Flow Rate…………………………………………….
15 GPM/900 GPH (56.8 LPM/3407 LPH)
7,200 gallons (27,255 liters) per 8-hour run
21,600 gallons (81,765 liters) per 24-hour run
Primary Filter………………...…………………………………
Mechanical Water Separator
Secondary Filter………………………………………………..
1, 3, 10, or 25μFine Filter or 3, 10μWater Block
Fuel Conditioner………………………………………………..
LG-X 3000 Inline Magnetic Conditioner
Plumbing………………………………………………………...
Stainless Steel
Inlet Port…………………………………………………………
1” Cam & Groove
Outlet Ports…….……………………….………………………
1” Cam & Groove
Operating Temperature...……………………………………...
41 - 104°(5 - 40°C)
Electrical………………………………………………………..
120V/60Hz/15A or 230V/50Hz/15A*
Pump/Motor…………………………………………………….
1/2 HP Rotary Vane Pump
Suction Capability (Primed)…………………………………...
15ft. Vertical lift or 100ft. horizontal run (lines >1”, primed)
Maximum Fluid Viscosity………………………………………
5 cSt
Clear Suction Hose……….…………………………………..
1”, 25 ft. (7.6 m)
Discharge Hose….…………………………………………....
1”, 25 ft. (7.6 m)
Outline Dimensions………………………………..…………..
≈48” x 22.5” x 25” (122 x 57 x 63 cm) (H x W x D)
Weight……………………………………………………………
≈160 lbs. (72.6 kg)
*At 50 Hz., nominal flow rate decreases from 15 GPM/900 GPH to 12 GPM/720 GPH.
!WARNING! This system is not meant for use with gasoline or any other flammable liquids having a flash point
less than 100°F (37.8° C). Use with gasoline or any flammable liquids at a temperature exceeding their flash point
presents an immediate explosion and fire hazard.

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System Components
Control and Safety Devices
• Vacuum & Pressure Gauges
• Inlet and Outlet Ball Valves
o Inlet Ball Valve
o Outlet Ball Valve (Discharge Port 1)
o Outlet Ball Valve (Discharge Port 2)
Pump/Motor
• 1/2 HP Rotary Vane Pump
• Pump Strainer
Primary Filter/Water Separator
• Water Separator
• Drain Valve
Fuel Conditioner
• Inline Magnetic Fuel Conditioner
Fine Filter
• Standard-issue 3μfine filter cartridge (other filter elements available)
Plumbing
• Stainless Steel

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System Operation
!WARNING! The whole system must be properly grounded for operator safety.
Note: It is recommended that only qualified, experienced personnel, familiar with this equipment, who have read and
understood all the instructions in this manual should operate and maintain the system.
Setup Procedures
To establish either fuel polishing mode, the user must attach both system hoses to the system in the proper configuration.
The Intake/Suction Hose is clear and see-through while the Discharge Hose is black and opaque. Both hoses are
equipped with quick disconnect cam & groove couplings.
1. First, attach the quick disconnect end of the clear Suction Hose to the Inlet Port of the system.
2. We highly recommend attaching a straight wand or pipe (cut at an angle) to the end of the Suction Hose in order
to reach the lowest part of the tank bottom.
3. The straight wand or pipe should be no less than the inner diameter of the Suction Hose.
Note: Never restrict the flow on the suction side of an MTC; e.g. by using a smaller ID hose or pipe attachment. This will
lead to excessive pump load, noisy operation, and ultimately pump damage.
Bypass Mode:
In bypass mode, the fuel bypasses the system’s Fine Filter(s) only to be ran through the Primary Filter/Water Separator
for the bulk removal of water, sludge, and particulate. To establish bypass mode:
1. Attached the quick disconnect end of black Discharge Hose to Discharge Port 1 (located to left of the fine filter).
2. Before running the pump, ensure the Inlet Ball Valve and proper discharge ball valve (Discharge Port 1) are in the
open position.
3. Also, ensure the other discharge ball valve (Discharge Port 2) and the Primary Filter/Water Separator drain ball
valve are in the closed position.
Fine Filtration Mode:
In fine filtration mode, the fuel is run through the system’s high efficiency spin-on Fine Filter(s) to remove free water and
fine particulate as small as 1 micron. To establish fine filtration mode:
1. Attached the quick disconnect end of black Discharge Hose to Discharge Port 2 (located to right of the fine filter).
2. Before running the pump, ensure the Inlet Ball Valve and proper discharge ball valve (Discharge Port 2) are in the
open position.
3. Also, ensure the other discharge ball valve (Discharge Port 1) and the Primary Filter/Water Separator drain ball
valve are in the closed position.
Phase 1
AXI recommends 3 phases to successfully polish a fuel tank. This will ensure all contaminates are removed and the fuel is
in optimal condition.
The goal of Phase One is to remove any free water and sludge from the bottom of the tank without mixing the water into
an emulsified state within the fuel. The Pump will start pumping as long as the system is primed (See Priming the System
section) and the suction lift is not excessive. The flow of the fuel can be observed in the see-through suction hose. Watch
for a steady flow of fuel into the container.
1. Setup up the system in the Bypass Mode configuration (see the Setup Procedures – Bypass Mode).
2. Place the Discharge Hose into a separate discharge waste container.

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3. To remove as much of the free water and sludge as possible, the Suction Hose (with a straight wand or pipe
attachment) should be placed at the deepest part of the tank.
4. Turn on the Pump and be prepared to immediately switch it off once the fluid begins to fill the discharge container.
5. Inspect the discharged fluid and resume pumping until the bulk water and sludge have been removed from the
tank bottom and only fuel is primarily discharged from the return hose.
6. Switch off the Pump and drain all water and debris from the hose and the Primary Filter/Water Separator (via the
drain valve) into an appropriate waste bucket or container.
Phase 2
The goal of Phase Two is to remove any additional free water, sludge, and large contaminants within the tank. This phase
will further clean the fuel and should be a precursor to using the more expensive spin-on filters. It should be noted that
meeting required cleanliness codes is typically not possible with Phase One and Two alone. Phase Two is simply used to
extend the life of the spin-on filters by removing the worst of the contaminants first.
1. Before turning on the Pump, ensure the system is still setup in the Bypass Mode configuration (see the Setup
Procedures – Bypass Mode).
2. Remove the Discharge Hose from the waste container and place it into the tank.
3. If possible, ensure the Suction and Discharge Hoses are placed as far apart as possible but note that in many
cases both hoses may have to be inserted through the same tank opening.
4. After verifying that both hoses are properly placed in the fuel tank and that the ball valves on the system are in the
correct position, switch on the pump and watch the clear suction hose for fuel flow.
Note: Depending on the amount of contaminants in the tank, we recommend you stop the pump shortly after priming and
check for free water and sludge by draining the water separator. It may be necessary to depress the air purge valve on
top of the separator after opening the drain valve. Repeating this process and observing the fuel flow will indicate how
long the pump should run before it is necessary to drain the separator.
5. The system should be kept running until clean fuel samples can be drained from the Primary Filter/Water
Separator. Once this is achieved, switch off the pump to prepare for the final polishing phase.
Phase 3
Phase Three is the most important phase in meeting specific cleanliness codes. Unlike the Primary Filter/Water
Separator, the spin-on Fine Filter typically uses an absolute rated media. Absolute filters have a very high efficiency and
will ensure that fuel leaving the system is clean to specification.
1. Before turning on the Pump, ensure the system is setup in the Fine Filtration Mode configuration (see the Setup
Procedures – Fine Filtration Mode).
2. After verifying that both hoses are properly placed in the fuel tank and that the ball valves on the system are in the
correct position, start the pump and monitor the Pressure Gauge on the Fine Filter head.
3. When the pressure reaches 20 – 25 PSI or the needle reaches the red area on the Pressure Gauge it is time to
change the Fine Filter (see the Maintenance – Servicing the Fine Filters section).
Draining and Storing the System
1. Remove the suction hose from the tank while the pump is still running and wait until system is purged of any
remaining fuel.
2. Place an appropriate container under the Primary Filter/Water Separator and Discharge Port 1.
3. Open their respective ball valve and use the air purge valve on top of the separator to make sure all of the fluid
can be drained from the system.

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Primary Inspection
Upon arrival, the system and accessories must be visually inspected before installation. Improper handling during
shipping may cause physical or electrical problems. Immediately report or note any damages to the shipper.
Checklist
 If the packing crate shows signs of damage inspect the system for damage.
 Check the entire system for damage that could indicate internal mechanical or electrical problems.
 Check pump/motor hardware and all plumbing connections for tightness.
 Check all electrical terminals and connections for tightness.

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Priming the System
The pump supplied with the system is NOT automatically self-priming and must not be run dry.
!WARNING! If the pump is allowed to run without fuel, pump damage can occur.
Priming Procedure
Before turning on the pump make sure the entire suction side of the system (suction hose, primary filter/water separator,
plumbing, and pump) is primed and filled with oil/diesel fuel. Running the pump dry could cause pump damage and pump
to not operate properly.

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Maintenance
The system should be visually inspected and tested a minimum of every six (6) months according to the
procedure below during light duty cycles. Monthly inspections are recommended for systems that are being used
in excess of an average of eight (8) hours a day and five (5) days a week.
Preventative Maintenance
Prior to performing the maintenance procedure ensure that:
1. All sources of power are isolated from the unit
Note: Proceed only after this has been verified and properly tagged.
2. Drain visible water and sediment from the primary filter (see Servicing Primary Filter/Water Separator).
3. Check system and all parts for corrosion and rust.
4. Check bolts on the pump/motor hardware for tightness, as pump/motor hardware can loosen after normal
operation for extended durations of time, due to vibration.
5. Check all plumbing joints for leaks, tighten fittings and joints as necessary, and remove accumulated fuel in the
leak-basin as necessary.
6. Inspect all filter(s) and separator.
Servicing the Pump
Check pump for leaks and worn vanes. We highly recommend carrying a spare pump. The MTC pump can be easily
changed in a matter of minutes by opening the unions and/or short hose connections. Spare part kits are also available for
all MTC pumps.
Keep the pump lubricated by pouring oil into pump head for storage.
Over time, the pump’s strainer can collect debris. It is good practice to frequently check the pump strainer and clean it to
prevent any flow restrictions.
Cleaning the Pump Strainer:
1. With the pump off, remove pump strainer cap on the pump/motor assembly with an adjustable wrench.
2. Once the cap is removed, fish out the mesh basket and rinse it off.
3. Once fully cleaned and dried, return the mesh basket to its original position and securely tighten the strainer cap.
Servicing the Primary Filter/Water Separator
It is recommended the Primary Filter/Water Separator be periodically serviced to prevent excessive water buildup. In the
case of a severely contaminated tank, the Primary Filter/Water Separator can also become clogged with sludge and
debris resulting in restricted fuel flow. The vacuum gauge reads the condition between the Primary Filter/Water Separator
and the pump and should provide some indication of a clogged filter via a pressure drop reading.
Servicing of Water Separator:
1. Ensure the system’s pump is turned off.
2. Close the inlet and outlet ball valves.
3. Place an appropriate container under the drain valve.
4. Remove the top plug to allow air in and fuel to flow out.
5. Open the drain valve and allow the water and sludge to drain.
6. Close the drain valve when you begin observing clean fuel.
Note: Disposal of fuel, associated waste, and filters must be in accordance with all applicable federal, state, and local
rules, laws, standards, and regulations.