BIO-VAC™ 270

Mobile Fuel Polishing & Tank Cleaning System

PRODUCT MANUAL

Intrinsically safe for gasoline, jet & diesel fuel,

and ethanol blends
Purifies fuel by removing sludge and microbial
contamination down to one micron
Removes fuel/water contamination to meet
engine manufacturer’s fuel cleanliness
requirements
Cleans your tank and purifies fuel with little to
no loss of product!
 BIO-VAC™ 270 Product Manual

Quality First. 100% Made in U.S.A.

Bio-Vac 270 Overview, Operation & Maintenance

TABLE OF CONTENTS
GENERAL OVERVIEW
Intended Use & Operating Principle . . . . . . . . . . . . . . . . . . . . . . . . . .3
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Features & Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Markets & Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

IDENTIFYING BAD FUEL

Contaminated Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
How to Take a Fuel Sample . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

WARNINGS & SAFETY

Preliminary Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Warnings & Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Precautions for Marine Applications . . . . . . . . . . . . . . . . . . . . . . . . . 15
Static Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Work Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

SYSTEM OPERATION
Get to Know Your System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
System Startup & Operation Modes . . . . . . . . . . . . . . . . . . . . . . . . . 20
Servicing Diesel Fuel Storage Tanks . . . . . . . . . . . . . . . . . . . . . . . . . 21
Servicing Phase-Separated E-10 Fuel Storage Tanks . . . . . . . . . . . . . . . . 22
Fluid Pickup Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Fuel Polishing & Tank Cleaning for Generator Base Tanks . . . . . . . . . . . . 24
Fuel Polishing & Tank Cleaning for Sub-Base Tanks . . . . . . . . . . . . . . . . 25
Draining System of Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

SYSTEM MAINTENANCE
Primary Bag Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Coalescer and Separator Replacement . . . . . . . . . . . . . . . . . . . . . . . 28
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

LIMITED WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

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INTENDED USE & OPERATING PRINCIPLE

This System is designed to be used with diesel fuel, gasoline, jet fuel, heating oil,
kerosene, and ethanol blended fuels for removing water and other contaminants
from fuel tanks.
The System has two (2) modes of operation:

1 REMOVE BULK WATER MODE

Used to remove bulk water and fast
filter when one or more inches of
water can be measured on the tank
bottom. This water can be pumped
directly into a waste container.

2 MAXIMUM WATER SEPARATING &

FILTERING MODE
Used to separate the remaining
water and filter the fuel after the
bulk water has been removed.

Please refer to page 21 in this manual for general instructions for each mode
of operation. Further instructions can found on pages 22–26.

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.

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 BIO-VAC™ 270 Product Manual

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TECHNICAL SPECIFICATIONS
Model BIO-VAC 270 Mobile 1620 GPH Fuel Polishing & Tank Cleaning System

This pneumatic system is designed to safely purify fluids including gasoline, diesel,
hydraulic, motor oils, and jet fuel to meet or exceed the latest engine manufacturer’s
cleanliness specifications. Free and emulsified water can be removed to less than
50 PPM. Particulate matter is removed to one micron.

• Chassis Construction: Powder Coated Steel

• Filter Housings: Stainless Steel
• Maximum Lift: 22 feet
• Pump Rated Flow Rate: Range 0 –1620 GPH (gallons per hour)*
• Water Trap: One (1) gallon US
• Compressed Air Required: 60 psi at 12 CFM = 17 GPM
• Compressed Air Required: 70 psi at 25 CFM = 27 GPM
• Width: 32” | Depth: 44” | Overall Height: 54” | Weight: 195 lbs.
• Pump 1” Air Operated Diaphragm
• Pickup Tube Hose: 25’ x 1-1/2” | Ball Valves with Cam-Locks
• Return Hose: 25’ x 1” | Ball Valves with Cam-Locks
• Drain Hose: 10′ x 1/2” | Ball Valves with Cam-Locks
• Vacuum Gauge: 2” Liquid Filled
• 24” Fueltec Primary Bag Filter
• Water Coalescer/Separator Micro-glass
PLEASE NOTE:
• Water Separator Stainless Steel/Teflon Air compressor not included.
• Air Regulator 3/8” This system requires a
60 psi at 12 CFM air
compressor for 17 GPM or
* Flow rates may vary with compressed air supply, filter type
and condition, length and size of hoses, and size and shape of
a 70 psi at 25 CFM air
fluid pickup and return tubes. compressor for 27 GPM.

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SYSTEM COMPONENTS
Fueltec’s BIO-VAC 270 Fuel Polishing System comes with:

(1) Quick-Disconnect Right Angle Fluid Pickup

Tube 40” w/ BIO-VAC Nozzle (#100191)
(6) 1-Micron Particulate Filters (#241004)
(1) 4 OZ Fuel Sampler (#100013)
(1) Stainless Steel/Teflon Separator Cartridge
(#241035)
(1) 5-Micron Water Separating Coalescer/Filter
(#241024)
(1) 25′ x 1-1/2” Pickup Tube Hose (#121043)
(1) 25′ x 1” Return Hose (#100503)
(1) 10′ x 1/2” Drain Hose [not shown] (#121039)

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 BIO-VAC™ 270 Product Manual

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FEATURES & BENEFITS

FUELTEC’S BIO-VAC 270 27 GPM / 1,620 GPH SYSTEM FOR GASOLINE, JET, DIESEL &
ETHANOL, BLENDS
• 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 rust, sludge, and solid contaminates from the
tank bottom fluid which may also contain water.
• The fuel/water mix leaves the fuel pump under pressure and is forced through
a filter/ coalescer where the tiny water droplets are made larger and separate
from the fuel. This type of water separator is commonly used on aircraft jet fuel.
• The Teflon separator prevents the water droplets from traveling with the fuel.
Separated water will drop into the water trap where it can be drained under
pressure.
• 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, dry 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.
• Separate and remove one ounce or 1,000 gallons without stopping the system.
• Tank cleaning is done with no loss of product.

FUELTEC’S QUALITY FIRST:

• 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.
• Meets engine manufacturers clean fuel requirements.
• Air operated diaphragm fuel pump intrinsically safe for all fuels.
• Static grounding reel for safety in class one areas.
• Variable speed control to avoid phase separation or emulsification.

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MARKETS & APPLICATIONS

A variety of fuels are stored worldwide, and are constantly in need of testing and
routine maintenance. Here are some of the opportunities for your business to
provide fuel polishing services.

RETAIL FUELING MISSION CRITICAL TRANSPORTATION

Gas stations and C-stores rely When the lights go out, Trucks and locomotives rely
on clean fuel. You can provide diesel engines have to on clean diesel. Your Fueltec
the solution for remediating operate—sometimes in a life system will have the answer to
phase separation in ethanol or death situation. You can keep their fleets running 24-7.
blended gasoline or removing offer systems tailored to any
contaminates from diesel fuel. application.

GOVERNMENT MARINE POWER GENERATION

Government agencies and Water and contamination must Diesel engines in industry have
military units rely on all fuels: be removed from both gasoline to operate without hesitation.
diesel, gasoline, and jet fuel. and diesel marine tanks for Automated fuel polishing
Fueltec’s systems for all fuels safe operation. Fueltec marine systems ensure fuel is clean
are in use worldwide. fuel polishing systems are and working to its best quality.
designed specifically for boats.

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CONTAMINATED DIESEL FUEL

• The fuel found above the tank bottom
water is usually clean and water free.
Off-Road Diesel Dyed Red
• Water being heavier than fuel will be
found at fuel tank bottoms.
• In fuel tanks, bacteria and fungus are
Bacteria & Fungus
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
Water while they float on the water.
• The dead microbes are heavier than
fuel or water and sink to the tank
bottom
Dead Bacteria & Fungus • When the fuel is added to a tank
where microbes are living, the
Sludge microbes get mixed with both the fuel
and water and can easily clog filters.
Bacteria living at the fuel-water interface feeds on
fuel but lives in water. Remove the water and the
bacteria and fungus will die!

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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.

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 BIO-VAC™ 270 Product Manual

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HOW TO TAKE A FUEL SAMPLE

USE FUELTEC’S 4OZ. FUEL SAMPLER:
• Take samples by lowering the sampler to the tank bottom.
• Sample valve will open and sampler will fill with fluid after 5-10
seconds.
• Lift the sampler above tank bottom and the valve will close. Fluid
will be trapped in sampler.
• After lifting sampler out of the tank; lower it into a sample jar.
• When the bottom valve contacts the jar bottom it will open;
draining the fluid into the jar.
• Check sample fluid for contaminates. Look for clarity and
uniform color, particles of rust and debris, sludge, or layers of
color may indicate bottom water or phase separation.

4oz. Fuel
Sampler
(#100013)

Fuel samples taken before and after tank cleaning with a

Fueltec Mobile tank cleaning system.

For complete instructions on how to take fuel samples, visit our website:
https://fueltecsystems.com/bad-fuel/how-to-take-fuel-samples/
Download full sampling instructions:
https://fueltecsystems.com/wp-content/uploads/2021/01/Fuel-Sampler-Kit-8-OZ.pdf

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PRELIMINARY PRECAUTIONS

CAUTION!
Do not operate this system unless you have read and understand all safety
warnings. This product operates in the highly combustible atmosphere of a
diesel or gasoline storage tank.

FAILURE TO COMPLY WITH THE WARNINGS AND SAFETY PRECAUTIONS

COULD CAUSE DAMAGE TO PROPERTY OR ENVIRONMENT, RESULTING IN
SERIOUS INJURY OR DEATH.

WARNING:
• This product operates in the highly combustible atmosphere of a diesel or
gasoline storage tank.
• This fuel polishing system should NEVER BE OPERATED inside a truck cargo
body, enclosed trailer, or within fifty (50) feet of an operating or hot engine,
motor or fuel dispenser.
• All work must comply with the latest issue of the National Electrical Code (NFPA
70), the Code for Motor Fuel Dispensing Facilities and Repair Garages (NFPA
30A), and any European, national, state, and local code requirements that apply.
• When servicing unit, use non-sparking tools and use caution when removing or
installing equipment to avoid generating a spark.
• To protect yourself and others from serious injury, death, or substantial
property damage, carefully read and follow all warnings and instructions
in this manual.

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WARNINGS & SAFETY

This section introduces the hazards and safety precautions associated with operating,
maintaining or servicing this product. Before performing any task on this product, read
this safety information and the applicable sections in this manual, where additional
hazards and safety precautions for your task will be found. Fire, explosion, or pressure
release could occur and cause damage to property, environment, resulting in serious
injury or death, if these safe service procedures are not followed.
You are working in a potentially dangerous environment of flammable
fuels, vapors, and fluid pressures. Only trained or authorized individuals
knowledgeable in the related procedures should operate, inspect, maintain
or service this equipment.

READ THE MANUAL

Read, understand and follow this manual and any other labels or related materials
supplied with this equipment. If you do not understand a procedure, call 1-828-212-
1141 to locate a qualified technician. It is imperative to your safety and the safety
of others to understand the procedures before beginning work. Make sure your
employees and any service contractors read and follow the instructions.

FOLLOW THE REGULATIONS

Applicable information is available in National Fire Protection Association (NFPA)
30A; Code for Motor Field Dispensing Facilities and Repair Garages, NFPA 70;
National Electrical Code (NEC), Occupational Safety and Hazard Association
(OSHA) regulations and federal, state, and local codes. All these regulations must
be followed. Failure to operate, inspect, maintain or service this equipment in
accordance with these codes, regulations and standards may lead to legal citations
with penalties or affect the safe use and operation of the equipment. OSHA fall
protection rules apply when working on above ground fuel storage tanks.

PREVENT EXPLOSIONS AND FIRES

Fuels and their vapors will explode or burn, if ignited. Spilled or leaking fuels and
used filters cause vapors. All used filters should be promptly placed in an approved
safety container until disposed of.
Even filling air compressor fuel tanks will cause potentially dangerous vapors in the
vicinity of the work area.

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WARNINGS & SAFETY

WORKING ALONE
It is highly recommended that someone who is capable of rendering first aid be
present during operation. Familiarize yourself with Cardiopulmonary Resuscitation
(CPR) methods, while working around fuel vapors. This information is available
from the American Red Cross. Always advise other personnel about where you will
be working, and caution them not to activate power tools or engines while you are
working with fuel filtration equipment. Use the OSHA Lockout/Tagout procedures. If
you are not familiar with this requirement, refer to OSHA documentation.
HAZARDOUS MATERIALS
Some materials may present a health hazard if not handled correctly. Ensure that
you clean hands after handling equipment. Do not place any equipment in the
mouth.

FAILURE TO COMPLY WITH THE FOLLOWING WARNINGS AND SAFETY PRECAUTIONS

COULD RESULT IN PROPERTY DAMAGE, INJURY OR DEATH.
FIRE HAZARD!
Do NOT use power tools (Class I Division I and Class I Division II) during the
operation or maintenance of equipment. Sparking could ignite fuel or vapors,
resulting in fire.
CHEMICAL EXPOSURE HAZARD!
Wear appropriate safety equipment during operation or maintenance of
equipment. Avoid exposure to fuel and vapors. Prolonged exposure to fuel may
cause severe skin irritations and possible burns.
REQUIREMENTS FOR USE
• Fueltec fuel polishing and tank cleaning systems are designed for use only by
trained personal. Free training is available at Fueltec’s factory located in Granite
Falls, NC USA. Call 1-828-212-1141
• The operation of Fueltec’s systems must be consistent with NFPA Code 30A,
OSHA regulations, and federal, state and local fire codes, and other applicable
local regulations.

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WARNINGS & SAFETY

OPERATING PRECAUTIONS
• NO SMOKING. Extinguish all open flames and pilot lights, such as on RV
appliances.
• TURN OFF cell phones and other electronic devices to prevent sparks which
could cause an explosion or fire.

PERSONAL SAFETY
Stay alert, watch what you are doing and use common sense when operating
or maintaining the system. Do not operate or maintain the system while you
are tired or under the influence of drugs, alcohol or medication. A moment of
inattention while operating 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. Also use non-skid safety
shoes, hardhat, gloves, and fall protection when appropriate.

CAUTION: BEFORE YOU START FUEL POLISHING!

DO NOT use Fueltec MOVE the fuel Keep air compressors,

fuel polishing systems polishing system to generators, vehicles,
inside an enclosed a SAFE OUTDOOR and other ignition
truck or trailer! WORK AREA. sources AT LEAST
25 FEET AWAY FROM
WORK AREA.

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 BIO-VAC™ 270 Product Manual

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PRECAUTIONS FOR MARINE APPLICATIONS

SPECIAL PRECAUTIONS SHALL BE FOLLOWED WHEN SERVICING MARINE FUEL TANKS:
• Have everyone leave the boat while servicing the fuel system.
• Shut off all engines, electric motors, and galley stoves and turn off the battery at
the main switch.
• Close all compartments, ports, windows, and hatches. The idea is to keep fumes
(vapors) out of all spaces while servicing fuel tanks.
• Don’t smoke and turn off cell phones.
• Attach a static grounding cable from fuel polisher to fuel tank to prevent static
sparks. (Refer to instructions for static grounding on the following page.)
• After fuel tank service, make sure all tank fittings are replaced, wipe up or wash
off any spilled fuel, open all hatches and ports, and let the boat air out.
• Operate the bilge blower for at least 30 minutes after service is completed.
• Sniff the bilge and engine compartment areas before starting the engine.
• Keep in mind that a bilge blower can’t remove vapors from spilled liquid gas, so
use your nose before turning the key.
• If there is a strong odor of gas, get everyone off the boat, notify the attendant,
and call 911.

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STATIC GROUND
ALWAYS ATTACH A STATIC DISCHARGE CABLE FROM THE FUELTEC SYSTEM TO A
LOW IMPEDANCE TRUE EARTH GROUND, AS DEFINED BY THE NATIONAL ELECTRICAL
CODE (NEC).

Ground rod driven

into the earth.

Connect static ground cable to earth ground.

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 discharge 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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WORK AREA INSTRUCTIONS

• Mark work area with orange colored safety cones placed in a radius of
at least twenty-five feet (25’) from fuel tank cleaning equipment, fuel
containers, and fuel tank openings.
• Place Flammable Liquid Warning Signs within work area.
• Keep work area clean, free of clutter and well lit. Cluttered 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 re-main at a safe distance of at
least forty feet (40’) from the work area.
• Be aware of all power lines, electrical circuits, water pipes and other
mechanical hazards in your work area, particularly those hazards below the
work surface 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 one or more Fire Extinguishers U.L. rated 10A-80B:C in the work area.
• Keep Air Compressor at least twenty-five feet (25’) feet from fuel tank cleaning
equipment, fuel containers, and fuel tank openings.

25 FT.

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 BIO-VAC™ 270 Product Manual

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GET TO KNOW YOUR SYSTEM

Air Bleed Valve

Return to Tank Valve 2
Return to Tank Port 2
Primary Filter Inlet Valve 1 (for filtered, dry fuel)
Primary Filter Inlet Port 1 Water Separator Housing
Separated Water
Primary Filter Housing Sight Tube
Fuel Pump Air Supply Valve

Direct Pump Port 3 Separator Drain Valve

(for filter only or bulk (not seen in picture)
water removal)
3-Way Valve

Air Pressure

3/8” Air Inlet

Vacuum Gauge

Inlet Port 1

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GET TO KNOW YOUR SYSTEM

Air Bleed Valve Swing Bolt Eye Nut (hand tighten)

Primary Filter Cover

Primary Filter
Inlet Valve 1

Vacuum Gauge
When gauge reads
15Hg, replace the
bag filter.

Filter Inlet Port 1

WARNING:
Set air pressure regulator not
Fuel Pump Air Supply Valve to exceed 70 psi at any time.

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 BIO-VAC™ 270 Product Manual

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SYSTEM STARTUP & OPERATION MODES

THE SYSTEM HAS TWO (2) MODES OF OPERATION:

1 REMOVE BULK WATER MODE

Used to remove bulk water and fast
filter when one or more inches of water
can be measured on the tank bottom.
This water can be pumped directly into
a waste container.
• Connect Pickup Tube Hose
to Primary Filter Port 1.
• Connect Return to Tank Hose
to Direct Pump Port 3.
• Open 3-Way Valve.

2 MAXIMUM WATER SEPARATING &

FILTERING MODE
Used to separate the remaining water
and filter the fuel after the bulk water
has been removed.
• Connect Return to Tank Hose
to Return to Tank Port 2.
• Connect Pickup Tube Hose to
Filter Port 1. Open Valves 1 and 2.
• Set 3-Way Valve to pump from
Primary Filter Housing to Water
Separator Housing.

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OPERATION OF THE SYSTEM TO SERVICE A

DIESEL FUEL TANK

1. Stick the tank bottom with water finding paste to find the depth of any free water.
2. Refer to a tank volume chart to estimate gallons of water in the tank
3. Close Air Bleed Valve, Inlet Valve 1, Return to Tank Valve 2, Separator Drain Valve, and Fuel Pump
Air Supply Valve.
4. Install Bag Filter and prime pump by filling Primary Filter Housing with one gallon of water.
5. Attach air supply from outside source to System.
6. Attach Fluid Pickup Hose to Inlet Port 1. Attach Fluid Pickup Tube, and attach Fluid Return Hose to
Direct Pump Port 3.
7. Adjust Air Supply Regulator to a maximum 70 psi.
8. Attach the Static Ground to a grounding rod driven into the earth to form a low impedance earth
ground. (Refer to page 16 for further instructions.)
9. Insert Fluid Pickup Tube with BIO-VAC™ Nozzle to the tank bottom.
10. Open Air Supply Valve and adjust flow rate to a very slow flow.
11. Open Inlet Valve 1 to fully open.
12. Place Return Hose outlet end in a waste tank.
13. Open Direct Pump 3-way Valve. The pump will start to cycle.
14. Pump all free water from tank bottom into the waste container or containers. Then close the Fuel
Pump Air Supply Valve.
15. Close Direct Pump 3-way Valve, and attach Fluid Return Hose to the Return to Tank Valve 2 on the
Separator housing.
16. Move Return Hose outlet end to the diesel fuel storage tank.
17. Open Air Supply Valve. The pump will start to pull fluid from the tank bottom.
18. Fluid should appear in the Sight Tube within two minutes.
19. Cycle pump until the System is full of clean fuel.
20. Watch Sight Tube for the presence of water. (Separated water on bottom, fuel on top.)
21. When water level reaches six (6”) inches, open the Separator Drain Valve and place drain hose into
waste container.
22. Control water level in Sight Tube with Separator Drain Valve and 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.)
23. The water level in the Sight Tube stops rising when all of the water has been separated from the
fuel storage tank.
24. When the Primary Filter Housing Vacuum Gauge reads 15Hg, replace the Bag Filter.
25. When the Water Separator Pressure Gauge reads 25 psi, replace the Coalescer.
26. The air operated fuel pump allows you purge fuel from the System after tank cleaning is completed.
27. After all water has been removed from the tank, close Inlet Valve 1 and open Air Bleed Valve on
top of the Primary Bag Filter Housing, close Return to Tank Valve 2, and place the Water Separator
drain hose in a waste container. Then open the Separator Drain Valve.
28. Stop fuel pump after all fluid has been removed from the System’s housings.

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 BIO-VAC™ 270 Product Manual

Quality First. 100% Made in U.S.A.

OPERATION OF THE SYSTEM TO SERVICE A

PHASE SEPARATED E-10 FUEL TANK

CAUTION!
Underground E-10 tanks must be 50% full before starting operation! The
maximum fuel pump lift with E-10 is 11 ft. from in tank product surface to
system’s fuel pump inlet elevation.
Do not use water separator on any ethanol blended fuel or more phase
separation may result.

1. Stick the tank bottom with water finding paste to find the depth of any free water.
2. Refer to a tank volume chart to estimate gallons of water in the tank
3. Close Air Bleed Valve, Inlet Valve 1, Return to Tank Valve 2, Separator Drain Valve, and Fuel Pump
Air Supply Valve.
4. Install Bag Filter and prime pump by filling Primary Filter Housing with one gallon of water.
5. Attach air supply from outside source to System.
6. Attach Fluid Pickup Hose to Inlet Port 1. Attach Fluid Pickup Tube, and attach Fluid Return Hose to
Direct Pump Port 3.
7. Adjust Air Supply Regulator to a maximum 40 psi.
8. Attach the Static Ground to a grounding rod driven into the earth to form a low impedance earth
ground. (Refer to page 16 for further instructions.)
9. Insert Fluid Pickup Tube with BIO-VAC™ Nozzle to the tank bottom.
10. Open Air Supply Valve and adjust flow rate to a very slow flow.
11. Open Inlet Valve 1 to fully open.
12. Place Return Hose outlet end in a waste tank.
13. Open Direct Pump 3-way Valve. The pump will start to cycle.
14. Pump all free water from tank bottom into the waste container or containers.
15. Pump an additional 150 gallons of fluid from the tank bottom to waste container.
16. After all bulk water has been removed, close Inlet Valve 1 and open Air Bleed Valve on top of the
Primary Bag Filter Housing. Close Direct Pump 3-way Valve and place the Water Separator drain
hose in a waste container, then opening the Separator Drain Valve.
17. The air operated fuel pump allows you purge the fuel from the System after tank cleaning is
completed.
18. Stop fuel pump after all fluid has been removed from the System’s housings.

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 BIO-VAC™ 270 Product Manual

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FLUID PICKUP TUBE

FOR FUELTEC’S MOBILE SYSTEMS

FuelTec’s Pickup Tube Hose

Type “D” Cam-Lock included with this system.

This system is equipped with a fluid extraction tube with a

BIO-VAC™ Nozzle to remove rust, sludge, particulate matter,
free and emulsified water from the tank bottom.

Even tiny droplets of water can be removed

with Fueltec’s exclusive BIO-VAC™ Nozzle
without phase separation or emulsification.

Fuel Tank Bottom

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 BIO-VAC™ 270 Product Manual

Quality First. 100% Made in U.S.A.

FUEL POLISHING & TANK CLEANING

FOR GENERATOR BASE TANKS

Tank cleaning using the FuelTec M-2 Supply &

Return Manifold, allowing supply and return
through one 2” tank fitting typical of generator
base tanks.

Pickup Tube Hose

Return to Tank Hose 2” Manifold

Fuel Tank Bottom

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 BIO-VAC™ 270 Product Manual

Quality First. 100% Made in U.S.A.

FUEL POLISHING & TANK CLEANING

FOR SUB-BASE TANKS

Vacuum fluid from the tank bottom on

one end and return the clean, dry fuel on
the opposite end of the tank.
If this method can’t be done...
Vacuum all of the fluid from the tank
bottom and return the clean, dry fuel to a
holding tank, them pump the fuel through
the system and back to the sub-base tank.
This method will polish all of the fuel.

Return to Tank Hose Clean, dry fuel

Pickup Tube Hose returning to tank

SUB-BASE TANK BAFFLES

Fuel Tank Bottom

BIO-VAC suction intake
on tank bottom

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 BIO-VAC™ 270 Product Manual

Quality First. 100% Made in U.S.A.

DRAINING SYSTEM OF FLUIDS

1. Drain fluid from hoses.
2. Close Primary Filter Inlet Valve 1 and Return to Tank Valve 2.
3. Open Air Bleed Valve.
4. Place waste Drain Hose end in empty waste oil drum.
5. Open Separator Drain Valve.
6. Open Air Supply Valve 1/2 open and run system until all fluid is
transferred from the System to the wasted oil drum.

Primary Filter Inlet Valve 1

Air Bleed Valve

Return to Tank Valve 2

Separator Drain Valve

(not seen in picture)

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 BIO-VAC™ 270 Product Manual

Quality First. 100% Made in U.S.A.

PRIMARY BAG FILTER REPLACEMENT

The System’s fuel pump duilds vacuum in the Primary Filter Housing. Change
Primary Filter Bags when Filter Housing Vacuum Gauge reads 15 Hg.

Open Air Bleed Valve on the cover, close the supply hose valve.
Run fuel pump for 30 seconds to drain housing.
Loosen swing bolt eye nuts and remove housing cover.

Remove bag filter hold down.

Remove and dispose soiled filter bag after each use.

Insert new filter bag into housing and seat bag flange on
housing baffle plate.

Insert filter hold down.

Install Filter Housing Cover and swing bolts into slots in cover.
Tighten swing bolt eye nuts hand tight then 1/4 turn more. (do
not over tighten)
Close Air Bleed Valve and open Primary Filter Inlet Valve 1.

Resume operation.

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 BIO-VAC™ 270 Product Manual

Quality First. 100% Made in U.S.A.

COALESCER REPLACEMENT
When the Pressure Gauge on the Water Separator Housing reads 25 psi, change the
Filter/Coalescer.

Remove soiled filter/ Insert a new filter/

coalescer from inside coalescer into
separator cartridge separator cartridge
onto boss.
The filter/separator
will hold to boss until
removed.

With filter/coalescer Hand tighten swing

inside the separator, bolt eye nut.
place it into the
water separator
housing, fasten with
3/8” nut and secure
housing top cover
with swing bolts.

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 BIO-VAC™ 270 Product Manual

Quality First. 100% Made in U.S.A.

COMMON REPLACEMENT PARTS

The BIO-VAC 270 comes with components stated on page 5 of this manual. Please
note this System requires a 60 psi at 12 CFM air compressor for 17 GPM or a 70
psi at 25 CFM air compressor for 27 GPM.

Part # Description

181019 Housing Top Seal Buna (Standard)

100518 Housing Top Seals (Pack of 6)

241004 Filter Bag 1-Micron x 24”

241040 Filter Bag 1-Micron x 24” (Pack of 6)
241041 Filter Bag 1-Micron x 24” (Pack of 25)
241042 Filter Bag 1-Micron x 24” (Pack of 100)
241007 Filter Bag 5-Micron x 24”
241043 Filter Bag 5-Micron x 24” (Pack of 6)
241044 Filter Bag 5-Micron x 24” (Pack of 25)
241045 Filter Bag 5-Micron x 24” (Pack of 100)

241024 Coalescer/Filter for BIO-VAC 270 20”

241039 Coalescer/Filter for BIO-VAC 270 20” (Pack of 12)

100010 M-2 Manifold for 2” Generator Tank Openings

200021 Pump Diaphragm for BIO-VAC 270 (Hytrel)

121043 Pickup Tube Hose 25’ x 1-1/2” w/ Cam-Lock Ends

100503 Return Hose 25’ x 1” w/ Cam-Lock Ends
121039 Drain Hose 10′ x 1/2” w/ Cam-Lock Ends

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 BIO-VAC™ 270 Product Manual

Quality First. 100% Made in U.S.A.

TWELVE (12) MONTH LIMITED WARRANTY

Fueltec Systems, LLC warrants the fuel filtration system equipment and components exclusively manufactured by
Fueltec Systems thereof to be as described in Fueltec’s specifications and to be free from defects in material or
workmanship under normal service, its obligations under this warranty being limited to a period of Twelve (12) months
from date of shipment from the Fueltec Factory as indicated by sales records. Fueltec’s obligations under this warranty
shall be limited to repair or replacement of failed materials found to be defective by Fueltec after inspection of the
returned goods at the Fueltec Factory.
This warranty excludes normal wear and tear parts, e.g. fuses, hoses, filter elements, seals, gaskets, pumps, pump
diaphragms, pump seals, valves and does not cover or apply to, and Fueltec shall have no responsibility, liability or
obligation under this Warranty or otherwise in connection with, any issue with a Fueltec product or part there for that
directly or indirectly is attributable to, is based upon or arises out of: (i) improper grounding, (ii) improper installation
or priming system, (iii) damage during shipment or after delivery, (iv) inadequate or improper storage, operation,
maintenance or monitoring, (v) misuse, (vi) user error or negligence, (vii) abrasive wear or corrosion, (viii) use of a
Fueltec product for a purpose or application other than the specific purpose or application indicated to Fueltec when
the product was ordered from Fueltec, (ix) power surge or brownout, (x) excess or inadequate pressure or voltage, (xi)
the particular substances, materials or products being filtered, or (xii) any non-Fueltec manufactured product or
component. Any change, modification or alteration to a Fueltec product and any attempt to repair a Fueltec product by
anyone other than Fueltec shall void this Warranty with respect to such product unless made at the request or with the
authorization of Fueltec and strictly in accordance with its directions and instructions.
To comply with this warranty:
1. Fueltec’s automatic systems are only to be operated as free standing, independent systems removing
water and contaminates from fuel storage tank bottoms, then returning the purified fuel back to the tank
without any connection to any other pump or piping.
2. Flexible pipe connectors shall be used on all piping connected to Fueltec’s automatic fuel polishing systems
to eliminate stresses in piping systems due to misalignment and thermal movement of the piping.
To obtain repair or replacement within the terms of this warranty, the product must be delivered, transportation pre-
paid by the warranty claimant, to the company’s main office shown above, with written proof of warranty coverage (e.g.:
company dated bill of sale, company approved dated bill of sale, serial number on product and written specification
of defect(s). In addition, a Return Merchandise Authorization Number (RMA number) must be clearly marked on the
exterior of the shipping container. A RMA number may be obtained by calling 828.212.1141. Failure to obtain a RMA
number and to clearly mark that number on the exterior of the shipping container may cause your shipment to be
refused by the company. In the event written proof of warranty coverage is not provided to company by claimant,
warranty coverage will be determined by the company based on the product’s serial number.
This warranty does not apply to any product or part thereof which, in the opinion of the company, has been damaged
through alteration, improper installation, freezing, mishandling, misuse, neglect, or accident. Running pump dry will void
the warranty. Missing or illegible serial number will void the warranty. If a product is sent to the company for warranty
evaluation without sufficient packing for product protection during shipping, warranty will be void. The extent of the
company’s liability under this warranty is limited to the repair or replacement provided above, and, in no event, shall the
company’s liability exceed the original purchase price paid to the company for the product part. No technical support
will be provided, and no warranty claims will be valid or provided under this warranty, for any product unless: (a) the
company has received full payment for such product and (b) claimant is not in default of any of its obligations to the
company regarding any FUELTEC product or company service.
This warranty is in lieu of all other express or implied warranties or liabilities. EXCEPT AS SPECIFIED IN THIS WARRANTY,
ALL EXPRESS OR IMPLIED CONDITIONS, REPRESENTATIONS AND WARRANTIES, INCLUDING, WITHOUT LIMITATION, ANY
IMPLIED WARRANTY OR CONDITION OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, NONINFRINGEMENT,
SATISFACTORY QUALITY, NON-INTERFERENCE, ACCURACY OF INFORMATIONAL CONTENT, OR ARISING FROM A COURSE
OF DEALING, LAW, USAGE, OR TRADE PRACTICE, ARE HEREBY EXCLUDED TO THE EXTENT ALLOWED BY APPLICABLE LAW
AND ARE EXPRESSLY DISCLAIMED BY THE COMPANY. TO THE EXTENT AN IMPLIED WARRANTY CANNOT BE EXCLUDED,
SUCH WARRANTY IS LIMITED IN DURATION TO THE EXPRESS WARRANTY PERIOD. This disclaimer and exclusion shall
apply even if the express warranty set forth above fails of its essential purpose. Any action for breach of this warranty
must be filed within a period of 90 days after the date any claim for such breach first accrues. In no case shall the
company be liable for any consequential or incidental damages for breach of any warranty. No person or representative
is authorized to assume for the company any liability other than that expressed herein in connection with any product.
No product has been certified or warrantied for Aviation use.
Fueltec Systems, LLC reserves the right to modify its warranty policy at any time, at its sole discretion.

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