Fueltec 950AW User manual

2014 Fueltec 950AW & 955SS Manual
Fueltec Models 950AW & 955SS
Mobile Fuel Tank Cleaning Systems
Operation Manual
Fueltec Systems LLC 828-212-1141
www.fueltecsystems.com

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2014 Fueltec 950AW & 955SS Manual
INTENDED USE AND OPERATING PRINCIPAL
This System is designed to be used with diesel fuel, gasoline, jet fuel, heating oil, ker-
osene, and ethanol blended fuels for removing water and other contaminants from fuel
tanks.
The System has three modes of operation:
1. Bulk Fluid Transfer without Water Separation or Filtration is used when several
inches of water are measured on the tank bottom. This water can be pumped directly into
a container without wasting filters or having to empty the Separator water trap.
2. Fuel/Water Separation and Filtration mode is used to separate the remaining water
and filter the fuel after the bulk water has been removed.
3. Filtration without Water Separation can be done at a higher flow rate than with water
950AW & 955SS Mobile Fuel Tank De-Watering and Filtration 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 sep-
arate from the fuel.
 The Teflon separator prevents 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 con-
tainer 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 vacuumed and
separated from the fuel storage tank.
 Tank Cleaning is Done With No Loss of Product
FEATURES
 Stainless steel filter housings to resist the acids found in today's diesel and
ethanol blended gasoline.
 Filtration down to one micron, water removal to less than 100 parts per
million.
 Exceeds ISO particle code of 18/16/13 to meet engine manufacturers clean
fuel requirements.
 Air operated diaphragm fuel pump intrinsically safe for all fuels.

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2014 Fueltec 950AW & 955SS Manual
Item SPECIFICATIONS Model 950AW Model 955SS
1Chassis Steel and Aluminum Brite Tread Standard Standard
2Air Diaphragm Fuel Pump flow rate* 0– 720 GPH 0– 2100 GPH
3Compressed Air Required at 40 PSI 10-16 CFM 20-25 CFM
4Maximum Lift wet 22 feet 22 feet
5Primary Stainless Steel Filter Housing 24 inch bag 24 inch bag
6Fuel Pressure Working Max. 40 PSI 40 PSI
7Separated Water Trap Capacity 2 gallons 2 gallons
8Filter/ Coalescer Micro-glass (Mil Type) CF-10 inch CF-20 inch
9Water Separator Teflon coated Stainless Steel S-11 inch S-22 inch
10 Supply & Return Fuel Hose with cam-lock connectors 1 inch X 12 foot 1 inch X 12 foot
11 Separated Water Sight Gauge Standard Standard
12 Swing Bolt Housing Cover for Quick Filter Change Standard Standard
13 Separated Water Drain while System is Running Standard Standard
14 Filter Condition Vacuum Gauge Standard Standard
15 Coalescer Pressure Gauge Standard Standard
16 Air Regulator and Pressure Relief Valve Standard Standard
17 Width X Length X Height.. Lbs. 32x47x60..250lbs. 32x47x61.. 325 lbs.
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.
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 appli-
cation, DO NOT use the machine until you have first contacted FuelTec Systems to determine if it can or should be
performed on the product.
* Flow rates may vary with compressed air supply, filter type and condition, length and size of hoses, and
size and shape of fluid pickup and return tubes.
General Safety Regulations
WARNING: Maximum air pressure setting not to exceed forty (40) psi.
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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2014 Fueltec 950AW & 955SS Manual
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 visitors
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 Air Compressor at least twenty five feet (25’) feet from fuel tank clean-
ing 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

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2014 Fueltec 950AW & 955SS Manual
FUEL TANK SAFETY
 Purge fuel tank (fill airspace inside the tank between any fuel and the top of
the tank) with argon or CO2 prior to drilling or sawing holes that penetrate the
tank to minimize the risk of explosion.
 Maintain a purged condition while installing fittings on a fuel tank.
STATIC GROUND
 Always attach a static discharge cable from the Fueltec System to the fuel
tank being serviced.
The flowing movement of flammable liquids like gasoline inside a pipe can build up
static electricity. Non-polar liquids such as gasoline, diesel, kerosene and light crude
oils exhibit significant ability for charge accumulation and charge retention during high
velocity flow. Static electricity can discharge into a fuel vapor. When the electrostatic
discharge energy is high enough, it can ignite a fuel vapor and air mixture. Different
fuels have different flammable limits and require different levels of electrostatic dis-
charge energy to ignite.
Electrostatic discharge while fueling with gasoline is a present danger at gas stations.
Fires have also been started at airports while refueling aircraft with kerosene. The use
of a static discharge cable can help to prevent or safely dissipate the build up of
static electricity.

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2014 Fueltec 950AW & 955SS Manual
Drip Pan
Filtered fuel return to
tank port 2.
Primary Filter Inlet valve 1.
Fuel Transfer Outlet 3.
Contaminant Drain Valve 4.
Vacuum Gauge
Sludge Filter Housing
Fuel Pump Air Valve 7. Sight Tube
Air Bleed Valve 5.
Water Separator
Housing
Pressure Gauge
Sludge Filter Inlet Port 1. Pressure Gauge
Stainless Steel
Stainless Steel
Locking Casters

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2014 Fueltec 950AW & 955SS Manual
Supply & Return Hoses… The Systems come with two (2) 1” X 12’ hoses
equipped with cam lock fittings and adaptors.
Fabricate suction tubes of the proper length to reach the tank bottom you are
servicing.
Suction and return tubes can be fabricated from PVC, Aluminum, Stainless
Steel, or iron pipe. Flexible suction tubes can be made from polyurethane tube,
nylon 11 tube, and PTFE (Teflon) tube.
Optional return manifolds are available from Fueltec.
Return Manifold for 2” tank opening is
shown with pickup tube inserted.
Pickup tube draws fluid from the tank
bottom. Clean dry fuel is returned to
tank through manifold ports.

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2014 Fueltec 950AW & 955SS Manual
Air Bleed Valve 6. Swing Bolt Eye Nut (hand tighten)
Primary Filter
inlet valve 1.
Vacuum Gauge
Sludge Filter inlet port 1.
Sludge Filter Cover
WARNING:
Set air pressure regulator not to
exceed forty (40) psi at any time
Fuel Pump Air Valve

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2014 Fueltec 950AW & 955SS Manual
1. Open air bleed valve 6., close primary filter inlet valve 1. (page 6)
2. Run fuel pump for 30 seconds to drain housing.
3. Loosen swing bolt eye nuts and remove housing cover.
4. Remove bag filter hold down.
5. Remove and dispose soiled filter bag after each use.
6. Insert new filter bag into housing and seat bag flange on housing baffle plate.
7. Insert filter hold down.
8. Install filter housing cover and swing bolts into slots in cover.
9. Tighten swing bolt eye nuts hand tight then 1/4 turn more. (do not over tighten)
13. Close air bleed valve 6. and open primary filter inlet valve 1. (page 6)
14. Resume operation.
BAG FILTER REPLACEMENT
FILTER BAG SELECTION
Gasoline: 1 micron to 10 micron bag
Kerosene: 1 micron to 10 micron bag
Jet Fuel: 1 micron to 10 micron bag
No. 2 Diesel: 5 micron to 10 micron bag
Note: Fuel tanks with heavy sludge build
up will require multiple bag changes.
Do not operate this system without filter
bags installed.

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2014 Fueltec 950AW & 955SS Manual
Coalescer and Separator Replacement
1. Close fuel pump valve and shut off air supply to system.
2. Open air bleed valve 5., open contaminant drain valve for one minute then close both
valves.
3. Loosen swing bolt eye nuts and remove housing cover.
4. Loosen 3/8” hex separator retaining nut.
5. Remove Separator cartridge. (coalescer may come with it)
6. Apply Vaseline to new coalescer o-rings and insert coalescer into separator.
7. Insert coalescer and separator into housing until 3/8” tie-rod protrudes through top of
separator.
8. Install 3/8” o-ring, washer, and hex nut onto tie-rod and tighten to 5 ft/lbs.
9. Install housing cover, swing bolts into place and hand tighten eye nuts then 1/4 turn
more. ( caution: Do not over tighten eye nuts)
10.Resume operation.
Water Separator
Filter/ Coalescer

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2014 Fueltec 950AW & 955SS Manual
Maximum Water Separation & Filtering
Connect Return to Tank Hose to Port 2.
Connect Pickup Tube Hose to Filter Port 1.
Open Valves 1. & 2.
Note 3-Way
Valve position
Fast Filter Without Water Separation
Connect Pickup Tube Hose to Filter Port 1.
Connect Return Hose to Port 4.
Open Valves 1. & 3. Close Valve 2.
Fuel will flow through primary filter only.
Note 3-Way
Valve positions
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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2014 Fueltec 950AW & 955SS Manual
Typical Fuel Tank De-Watering and Filtration:
Underground and Aboveground 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 inch 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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2014 Fueltec 950AW & 955SS Manual
First Start Up of the System to Service a Fuel Tank
1. Close air bleed valve 6. page 6, contaminant drain valve 8. pages 7, and fuel
pump valve 7..
2. Install Bag Filter as shown on page 9.
3. Prime pump by filling sludge filter housing with one gallon of product.
4. Attach 40 psi air supply from outside source to fuel pump valve 7.
5. Attach fluid supply hose to sludge filter port 1.
6. Attach fluid return hose to return flow control valve port 2.
7. Attach pickup supply & return tubes & manifold to hoses.
8. Adjust air supply regulator to a maximum 40 psi.
9. Attach the Static Ground to the tank being serviced with the spring clip.
10.Insert Manifold into fuel storage tank opening and connect hose.
11. Insert fluid supply pickup tube into the tank manifold to a point just under
the fluid level until the fuel pump is primed.
12. Open air supply valve 7. & adjust flow rate
13. Open Supply Port Valve 1. full open.
14. Open Return Valve 2. Pump will start to cycle.
15. Fluid should appear in sight tube within three minutes.
16.Cycle pump until the system is full of clean fuel.
17. Close supply port valve 1. until vacuum gauge reads 12Hg. Then open
supply port valve 1. full open.
18.Move the fluid pickup tube to the lowest portion of the fuel tank to remove the
contaminates only after steps 1 thru 16 have been completed.
19. Watch sight tube for the presents of water. (water on bottom fuel on top)
20. When water level reaches six (12”) inches;
open contaminant drain valve 8. and place drain hose
into waste container.
21. Control water level in sight tube with drain valve 8.
& return to tank valve 2. (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.
22. The air operated fuel pump allows you purge the fuel
from the system after tank cleaning is completed.
(this can’t be done with an electric pump)

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2014 Fueltec 950AW & 955SS Manual
23. Observe Vacuum Gauge 3. two minutes after fluid appears in sight tube; The
initial Vacuum reading will be determined by the elevation of the supply port 1.
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.
24. Observe the Pressure Gauge. When the gauge reads 22PSI, the coalescer fil-
ter needs changing.
Use only Fueltec 24” Bag Filters in this
System
1 micron…. 1M24
5 micron…. 5M24
10 micron…. 10M24
Use only Fueltec Filter/ Coalescers
in this System
CF-10 for the 950AW
CF-20 for the 955SS
Water Separators
S11 for the 950AW
S22 for the 955SS

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2014 Fueltec 950AW & 955SS Manual
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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2014 Fueltec 950AW & 955SS Manual
SUCTION HOSE
RETURN TO TANK HOSE
FUEL TANK BOTTOM
CLEAN DRY FUEL RETURNING TO
TANK THROUGH SHORT PIPE
SUCTION INTAKE ON
TANK BOTTOM

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2014 Fueltec 950AW & 955SS Manual
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 MANIFOLD
SUCTION INTAKE ON
TANK BOTTOM
1/2 INCH PIPE FUEL
PICKUP SUCTION
TUBE

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2014 Fueltec 950AW & 955SS Manual
Equipment Inspection Checklist
To insure the proper and safe operation of all Fueltec Systems, LLC equipment
and to initiate the warranty coverage, the owners or owners agent must in-
spect the Equipment and verify that this manual was read and understood by all
of the operators using this equipment. This manual shall be kept with the equip-
ment at all times.
In the event that this system or any part of this system shall not operate
according to the descriptions contained in this manual or should any fluid leak-
age be observed while operating this equipment;
STOP USING THE FUELTEC EQUIPMENT, and Fueltec Systems LLC
should immediately be notified at :
AREA [phone] or [e-mail]
Validate your warranty
I certify that I have inspected the Fueltec Systems Equipment, read and under-
stand this manual, and will instruct other potential operators of this equipment
on the safe operation of this equipment.
this day of 2013
By:_________________________ Print Name______________________________
Owner/Agent
Please copy for your records and return this signed and dated original to:
Fueltec Systems, LLC P.O. Box 487, 3821 N. Main St. Granite Falls, NC 28630 to
initiate your warranty coverage.