Diesel Performance Products, Inc. FASS FF-1001, Installation Manual

Page 1: ...INSTALLATION MANUAL APPLICATION T 220G 220GPH 16 18psi CLASS 1 CLASS 8 Requires a Fuel Line Kit Revision Date 10 12 2015 ...

Page 2: ...to our network of dealers so our customers needs and expectations will be exceeded To help insure you receive the proper system and customer support at the local level FASS has a VIP and Authorized Dealer network representing FASS products This is one reason you must purchase through a dealer to comply with our warranty policies If you do not there is no warranty We recommend you go to www FASSrid...

Page 3: ...its with UIME in the model number Do Not Remove any factory installed secondary fuel filter Removal of a factory installed secondary fuel filter may void the engine manufacturer s warranty This is the fuel filter between the engines fuel pump and the injectors Be sure that the serial on this installation manual matches that of the outside of the box Keep debris from entering the internals of the s...

Page 4: ...s in accuracy and efficiency due to training communication and our relationship with our dealer network we recommend a ViP FASS dealer for the installation They are prepared to install the FASS fuel pumps with the most effi ciency If a situation problem arises during the installation they are the most pre pared for that situation problem DPPI is not responsible for any installation mis takes 5 If ...

Page 5: ...event engine damage H Coolant Heater R Fuel Return to Tank E To Engine Serial Number Location G Fuel Pressure T Fuel Inlet Electric Heater Port 2nd Electric Heater Port Installation Step 1 Install Electrical Harness Step 2 Prepare Suction and Return Lines Step 3 Mount Fuel System Step 4 Install Fuel Line Step 5 Check Installation ...

Page 6: ...Contents WH 1005 BR 2001 MP 9050 WE 1001 ...

Page 7: ...Mounting Package Contents Mounting template RS 1001 RS 2684 Spade Terminal Ring Terminal 10 273 4 Locking Nut 3 8 3 WA 1001D 4 3 8 16 x 1 1 2 Hex Bolt 3 Hex Bolt 1 4 20 13 4 ...

Page 8: ...Connect the Red lead to the ON terminal of the ignition switch or a terminal on the circuit breaker board that is hot when the key is on Use a test probe to locate the hot side of the circuit in the fuse block F Using the ring terminals connect the green wire of the wire harness to the negative post and the red wire to the positive post of the battery H Properly secure all electrical leads and har...

Page 9: ...NOTE ATTENTION While installing fittings into Titanium pump DO NOT Apply side pressure to draw tube of pump Improper Proper ...

Page 10: ...to inspect for burs or flare imperfections When cutting fuel line make sure to blow out line to keep debris from moving forward B Using thread tape install the fittings into the E and the T ports on opposite end Torque to 40 lb ft Note Do Not Put Thread Tape on Flare of Fitting The use of thread sealant is not recommended C Attach BR 2001 to back of system using the spacers and 1 4 bolts Use the t...

Page 11: ...ngs located on filters Attach to system and tighten appropriately E Connect factory plug into the FASS harness Turn key to on With pump operating turn pump over liberally spray WD 40 or equivalent into water separator nipple lubricating the Gerotor F Assemble to frame using the 4 3 8 bolts flange nuts placing the RS 1001 between the frame and bracket An optional accessory is SFB 1001 Note O Ring m...

Page 12: ... Popular Usually on 1993 Trucks Older except 359 Peterbilt next selection Single Draw Single Return Line System FASS fuel line kit FLK S02 should have all of the product to complete this process B3 359 Peterbilt Single Draw Out of Cross Over Fuel Line Single Return Line System Dual Tank Recommendation 1st Choice Convert to a complete Double Draw Double Return Line System FLK S03 or Dou ble Vent Re...

Page 13: ...ollowing procedures referto this procedure when necessary B1 Assemble fuel line into female hose fitting reverse threads then apply a modest amount of oil to the interior lining B3 Oil male JIC swivel 90 or straight and assemble into female end Step 4 Double Draw Double Return Fuel Line System Caution Do Not use sealant on AN fittings Only use sealant on threads installed into pump assembly or joi...

Page 14: ...d for return fuel Measure mark this line as it will con nect to the 90 fitting of the T in this location K Torque all connections to 18 ft lbs Secure the fuel line and all fittings Continue to Step 5 F Assemble a 8 AN hydraulic fitting into one end of the remaining fuel line Route this fuel line from straight fitting of the T to the return port in the fuel tank mark cut G Caution Route the side wi...

Page 15: ...ra port some where at the top of the fuel tank Remove the plugs and install the 8 ANx5 16 NPT into each tank it may be necessary to use a brass bushing B1 Assemble fuel line into female hose fitting reverse threads then apply a modest amount of oil to the interior lining B3 Oil male end of 90 JIC swivel fitting and assemble into female end B4 The male portion should tightened all the way as seen C...

Page 16: ...with an R Route to the port in the fuel tank being used for return fuel Measure mark cut D In the same manner as previously covered route and loosely connect the fuel lines discussed in this section to the appropriate points of connection E Torque all connections to 18 ft lbs Secure all fuel lines and fittings Continue to Step 5 ...

Page 17: ...ep 5 and you may go directly to step 6 C Disconnect fuel line from engine Connect to T port of the FASS E Route fuel line to open port engine or FASS measure and cut D Assemble a 10 AN hydraulic fitting into one end of the 10 fuel line and loosely connect to either the FASS or the engine F Assemble a 10 AN hydraulic fitting into the cut end Remember clocking of the fuel fittings may be necessary t...

Page 18: ...eturn System Caution Do Not use sealant on AN fittings Only use sealant on threads installed into pump assembly or joining fittings These lines must be the exact length on both sides Return line from FASS with straight ends to cross member where the line will T off E Assemble the T using 1 3 8 NPT T 2 8 ANx3 8 MPT 1 8 ANx3 8 MPT 90 as seen in the photo From T to each fuel tank with 2 straight fitt...

Page 19: ... as it will con nect to the 90 fitting of the T in this location M Torque all connections to 18 ft lbs Secure the fuel line and all fittings Continue to Step 5 H Assemble a 8 AN hydraulic fitting into one end of the remaining fuel line Route this fuel line from straight fitting of the T to the return port in the fuel tank mark cut I Caution Route the side with the exhaust first as it may be necess...

Page 20: ... reducer and secure Thread tape bushings and install them on the T NOTE Not all configurations will be able to be assembled this way Install the vent line on the top portion of the T and the FASS return line into the middle of the T Repeat previous steps on other tank to install the Double Vent Line Return Kit Step 6 Double Vent Line Return System O The below picture illustrates the configuration ...

Page 21: ... Most Preferred Easiest 1 Drill and tap a 3 8 fpt in the thicker band of aluminum as seen 2 If possible install the fuel tank vent in this port and connect the FASS Option 2 Ways of Producing Extra Ports Bung fitting Note The Red Plastic Plugs located in the H ports can stay in place fuel will not flow through these ports Coolant can be plumbed into these ports to heat the fuel in the Winter month...

Page 22: ... Separator Filter Install FS 1001 on water separator nipple without the draw tube Make sure to insert O Ring provided on nipple Note O Ring must be put back on suction side of pump Failure to do so can result in priming issues cavitation or pressure loses Step 7 Review Installation Secure Connections ...

Page 23: ...l Performance Products Inc will repair without cost any product found to be defective during the warranty period parts only or at its option will replace such products in exchange for the product Repair or replacements are warranted for the remainder of the original warranty peri od All Warranty claims are subject to approval by Diesel Performance Products Inc A Return Material Authorization RMA n...

Page 24: ...5 4M Donaldson P551000 10M Donaldson P551311 3M Donaldson P551001 10M Donaldson P551313 3M Fleetguard FS1282 14M Donaldson P553203 3M Fleetguard FS 1000 10M Donaldson P557440 6M Fleetguard FS 1001 10M Fleetguard FF5320 2M Fleetguard FS 1009 14M Fram P8334 2M Fleetguard FS 1212 14M Hastings FF1079 2M LuberFiner LFF8011 Wix 33352 6M LuberFiner LFF8000 Wix 33528 2M Motorcraft FD818 14M Wix 33674 2M W...

Page 25: ...NOTES ...