Fuel Pro® FH230 Series ilter/Separator/Warmer Installation Instructions Parts List - 3345705 § vert Ga and Aserby ¢ [o-ring sousos [cover Asenbiy a0asras 8 €_|retsovn Seg aneaeai § ite: Eent nccdes Grama Fan D-Rings) Bahan [O-Ring Pack Incuced wit each [apaagan ¢_|enlcamart cement . Biodeso| Gasket ack oly requires tor >85 tel fovianed Te ave Sven neues 1 Frnt neste Serna 7 [ova is 6 K_| Fost, Heaee Seepage [12VD0 Como Thermo/ieater | SO80TS3 5 24VOC Combo Therno/Heater | 3952119 § Cala Wrench Paste souaast § Colar Wrench Meta soeasas 5 Wot [WF Wring Hares 960729 6 Shown [WiFLED) 2046670 § a ‘CAUTION: These instructions are intended for use by professional mechanics who are Walned inthe proper Frzaerc use of power and hand tools, using appropriate safety precautions (including eye protection).page 2 Service Kit Installation ‘This system must be installed between the fue! tank and the transfer fuel pump. This system can be used as the only fuel flter in the fuel system by removing the existing fiter and heads, or remove the titers only and replace with special Diverter Caps (sold separately - see Table 1). Note; If the Fuel Pro® is used as the primary filter and a secondary filter is required, ‘secondary filter life may be extended. ced 3045484 8 ‘3045105 seusnes S| [seesters [wats | 304588 S 4S WARNING: When diese! fuel is circulated through an operating engine, it can become very hot. To prevent personal injury: AS Scaling nazard! Do not allow heated liquid fuel to come in contact with eyes or unprotected skin. Always allow the engine and fuel to cool to ambient temperature before replacing the fuel filter or performing service operations which could result in the spillage of fuel from the fuel system. If this is not possible, protective clothing (face shield, insulated hat, gloves, apron) must be worn. AS Heated diese! fuel can form combustible vapor mixtures in the area around the fuel source. To eliminate the potential for tire, keep open flames, sparks or othor potential ignition sources away from the work area, and do net smoke during filter replacement or service operations which could result in the escape of diesel fuel or fuel vapors. AN Always pertorm engine or vessel fuel system ‘maintenance in a well ventilated area that is. kept free of bystanders. raver co Installing the Fuel Pro Service Kit With the engine shut down and et ambient temperature, close the fuel shutoff vaive (it equipped) and place a suitable container under the fuel fiters. Remove the primary fuel fiter element assembly, sedimenter, andlor water separator. Drain the used element and dispose of itin an environmentally responsible manner, according to state andior federal (EPA) or national tecommendatons. The fuel can be retumed to the tank, For a one-flter system, select the required secondary fter head diverter cap from those listed in Table 1. The required part number is determined by the size of the spin-on fiter stud and the filter sealing surface diameter. The Fuel Pros designed to provide total ‘engine filtration, when fitted with the appropriate filter to meet OEM engine specifications. Installation of the Fuel Pro should be on the suction side of the fuel system. Introducing the Fuol Processor to more than 30 Ib/n® (2.07 bar) at any time can cause unit failure or give false information regarding filter life. Install the diverter cap on the secondary filter head as follows: ‘a. Remove the secondary fuel fitsr element, drain and dispose of it in an environmentally responsible manner according to government fegulations (L.e., state/province, federal, etc.) ‘The fuel can be returned to the tank. ‘Lightly lubricate the seal on the top of the iverter cap with clean engine oil. ¢. Thread the adapter onto the secondary filter stud and tighten by hand plus 1/2 turn turtner. d. Install ha "Do Not Remove" sticker on the diverter cap. Mount the Fuel Pro in the desired location keeping the following points in mind: a, Mounting the Fuel Pro directly on the ‘engine is NOT RECOMMENDED. . Mount vertically with the cover and element pointing up. c. Make sure there is enough top and side clearance for the cover to be conveniently removed for fiter replacementFraser co page 3 4. CAUTION: The Fue! Pro® functions BEST when installed so that the Filter Element is above the "FULL" level of the fuel tank. The housing can be installed up to 6' (1.8 m) below the “FULL” level of the fuel tank. Installing below the “FULL™ level causes tho starting level to be higher than normal. if mounted below full tank level, a shut off valve will be required at the inlet to allow filter changes without overflow of fuel. Mounting below 6! (1.8 m) eliminates the Seeing is Believing functionality. '5. Route the fuel supply line from the fuel tank to ‘he Fuel Pro inlet (See Figure 1). Route a fue! line {rom the Fuel Pro outlet to the fuel pump inlet. Fetsip Figure 1 — Fuel Pro Connections 5. Tominimize restrictions, observe the following ‘guidelines when plumbing the system. Keep the fuol ine routing as smooth as possible with no low hanging loops which can trap water. Bb. Use 90° elbows only when necessary. . Ifthe fuel hases are made up to length on the job, be suro that the ier liner of the fuel those is not cut by the fitting, creating potential check valve effects. Also make sure hoses are clean and free of dabris before installing, 6. Apply Tetion® pipe sealant tothe inlet and outlet those threads and connect the hoses to the unit 4 CAUTION: To avoid damaging the aluminum fuel processor body, do not overtighton fuel lines or fuel line fittings. Installing a WIF (Water In Fuel) Probe 1. Install the WIF Probe (2911940 S) into the ‘bottom af the Diesel Pro (see Figure 2). Torque 1020-25 invibs (2.3-2.8 Nem). 2. Install the WIF wiring harress (3950729 S) ‘on WIF Probe. The hamess has the following connections: 12" (304.8 mm) black ground lead ‘with a 9/8" (9.59 mm) diameter loop end and a 72" (1828.80 mm) green WIF wire. Figure 2 — WIF Probe installation 3. Drill 1/2" (12.70 mm) hols in the dash or control panel where the WIF LED (3948670 S) is to be located. ‘& Installation must have 1.5" (98.10 mm) of learance behind dash or control panel . Use caution not to damage nearby ‘components when dniling 4, Install WIF LED by pressing firmly into the drilled hole. 5, Comect the 4" (101.60 mm) black ground wire on WIF LED to a ground source. Attach adaitional black wire a8 needed 6, Connect the 12° (304.8 mm) black ground lead with a 3/6" (9.53 mm) diameter loop end on the WIF wiring hamess to ground source near Fuel Processor it applicable), 7, Conect 72” (1828.80 mm) green signal wire (on WIF wiring hamess to 4* (101.60 mm) green signal wire on WIF LED. Use additional green wire as needed. 8, Locate 12 VDC or 24 VDC power sourca, Run red wire from power source to 4* (101.60 mm) red wire on WIF LED Add a 10 A indine fuse (not included), (See Figure 3)page 4 Figure 3 ~ WIF Wiring ‘Note: Use appropriate connectors to attach the ‘wires. To test the WIF indicator, pour water into the body of the fuel processor untl it covers The WIF probe. The WIF LED should illuminate. For unheated fluid, the volume of fluid necessary to turn the WIF indicator on is 6.15 02 + .07 oz (182 mL + 2 mL), for heated fluid the volume necessary is 3.08 o2 s .07 oz (gi mL +2mb). Fuel Heating Options Note: The Engine Retuin Fuel Haat and Engine Coolant Heat options apply ONLY to the heater base shown in Figure 4. Ifthe bottom plate is fat with 1/2" NPT ports, only an Electric Preheater can be used. Engine Return Fuel Heat Electronic unit injected engines can use retum fuel as the fluid heat for the Fusl Pro®. Route the return fue! line from the engine into the Heater Base of the Fuel Pro (see Figure 4). Either heater port will work as an inlet. Connect a second fuel return line from the Heater Base to the fuel tank return port Figure 4 — Heater Base F1296FGO Engine Coolant Heat To use engine coolant as the Fuel Pro heating fluid, connect a hose (Braided #8 or #8 hose) irom the high pressure side of the engine coolant system to the Fuel Pro Hester Base. Either heater port will work as an inlet. Route another hose trom the: Heater Base to a low pressure port in the coolant system. DO NOT route into the cab heater system. (See Figure 1.) Optional Electric Preheater ‘The electric preheaters available for the Fue! Pro are 12 or 24 VDC Combo Therma/Heaters or 120 VAGIST W Heaters. To Install a 12 or 24 VDC Combo ThermojHeater: 1. Either one or two DC heaters can be installed, depending on the application. Electric preheaters are optional and must be ordered separately. Table 2— 12.and 24 YDC Combo ThermorHeaters 1200 Combe Thoma Meatr [BE VOC Combs Terma Heater lf Combo Thermo/Heaters are not already installed, remove the 1/2" NPT plugs from tho Dottom plate of the Fuel Pro and instal either one ortwo Combe ThemalHealers. Torque to 15-30 ‘felbs (203.40.7 N-m), (See Figure 5.) | 7 a7 Canta Thermo Hoter Figure 5 - Combo Thermo/Meater Installation 3. Connect the Power Lead of each heater to the accessory side of the ignition switch. (Lisa of a 25 A fuse is recommended but not included in Fual Pro kit, Use a relay ifthe equiprent ignition ‘circutt wil not handle a minimum of 20 A. See Figure 5.)page S iy roe: Figure 6 — Fuse and Relay Connections To Install 120 VAC Heaters: 1+. Ether one ortwo AC heaters can be installed, depending on the application. Electric preheaters are optional and must be ordered separately Table 3 - 120 VAC Heaters es Description ‘SMSIZTS | 120VACTS W Hes 3048126 S| single corset Y GordsetY con a processor and Bock neater suwnes | Yfoue 2. If120 VAC Heaters (2) are not already installed, remove the 1/2" NPT plugs from the bottom plate of the Fuel Pro and install the 120 VAC Heaters. Torque to 15-90 ftbs (20.3-40.7 Nim). (See Figure 7) ] - 1 Figure 7 — 120 VAC Heater installation FraveFco 3. Two types of cordsets are available for the 120 VAC/75 W heater(s) (see Figure 6). 4, Plug the power cord into a 120 V receptacle. ‘Single Cordset -_— 2 0829) ——_j & Partrumboe pig? Deaes 120" (998 8 em) Figure 8 ~ Electric Heater Coraisetspage 6 Installing the Electric Combo Heater and WIF Sensor on Metric Units To install an electric cambo tharmafhaater on a metric Fuel Pro®: 1. Ifa heater is not already installed, remove the plug tram the bottom plate of the Fuel Pro and inatall the electric Combo Thermo/Heater. Torque to 15-30 ft-lbs (20.3-40.7 N.m). (See Figure 9.) yay — # are Figure 9 ~ Electric Combo Heater and WIF Location 2. Attach the Chassis Ground Hamess. Connect the black wire to the power supply and the white wire 0 application ground. (See Figure 10.) To Install a WIF sensor on a metre Fuel Fro: 1. Ifa WIF sensor is not aiready installed, remove the plug from the bottom plate of the Fuel Pro and install the WIF sensor. Torque to 15-30 ft-lbs (20.3-40.7 N-m). (See Figure ®.) 2. Attach the WIF Wiring Harness. Connect the black wire to the application grounc. It you have the optional LED indicator (part number 3946570 S) , connect it using the groen wie. (See Figure 10) FraeaecD. Figure 10— WIF Wiring Hamess and Chassis Ground Hames Filter Change Procedure 1, Tum ot the engine. Loosen the vent cap to break the ai lock in tne fer 2. Open the drain vaive and drain the fuel level ‘below the collar, then close the drain valve. 3. Using the Collar/Vent Cap Wrench (part number 3044451 5 (plastic) or 3044448 S (mete))), ‘emove the clear cover trom the fuel processor bby removing the collar. Discard the o-ring from ‘the base of the cover. (A new o-ring seal is Supplied wih the new fiter.) For Biodiesel ‘applications use gasket pack 3950445 8. Gasket ccoloris green and MUST be changed with every fiter change. Remove the fier element from the Fuel Pro by pulling upward and twisting slightly. Be sure the sealing grommet is removed trom the ‘center stud. Figure 8 ~ Coflar’Vert Cap Wrenchpage 7 4, Install the new fiter element (supalied with «a Sealing Grommet already inserted into the element) on the processor center stud by pushing down and twisting siighily. After checking 10 make sure the new o-ring seal (supplied with the fiter) at the base of the caver isin place, instal the cover and collar. Hand tighten the collar until seated. Do not use tools to tighten. Table 4 ~ Replacement Filters art tum = FS19761_| fleiax™ StataFow™ 2 micron F510624 | feVixSraaPore 7 mera Bien SraaPore 10 micro7 EM SraaPore 25 micron Ele SrataPore 10 nin (ole ze) Eieinx SraPore 25 ier [pls ze) FS10768 5. Remove the vent cap from the top of the clear ‘cover by tung the vent cap counterclockwise Fil the clear cover with enough clean fuel to ‘cover the bottom haif ofthe fillar element. Make ‘sure the new o-ring (supplied with the fer) is installed on the vent cap. Reinstall the vent cap and tighten by hand only. 6. Start the engine. When the lubrication system reaches ts normal operating pressure, increase ‘engine RPM for one minute. ‘Note: The clear fiter cover wil nt fl completely during engine operation. It wil gradually fil over time as the fiter becomes clogged. The fiter element does not need to be changed until the fuel level has risen to the top ofthe: fill element riming the System 1. Check to make sure the orain valve at the base of the Fusl Pro® is closed. 2. Remove the vent cap from the top of the clear Cover. Fill the Fuel Pro full of clean fuel. Reinstall the vent cap and tighten by hand only. 3, Start the engine. W/hen the lubrication sysiem ‘reaches its normal operating pressure, increase engine speed to high idle for one to two minutes. Alter the air is purged, loosen the vent cap until the fuel level lowers to just above the bottom of ‘the collar. Tighten the vent cap by hand only. Fiasco Note: The clear filer cover will not fil completely during engine operation. It will gracually fil over time and the fuel level will rise as the titer becomes clogged. 4. Hand tighten the collar again while the engine is running. To evoid damage, do not use tools to tighten the collar. 3 CAUTION: To avoid damaging the aluminum fuel processor body, do not overtighten fuel lines or fuel line fittings. Emergency Temporary Filter Replacement 1. Follow Steps 1 through 3 of the "Filter Chango Procedure" on page 5. 2. It there is a filter grommet on the filter stud, remove it. 3. Install an engine spin-on fiter (part number F105, for example} on the threaded stud. 4. Install the cover, spring, seal and collar over the {iter tor later reuse and to guard agains! loss. 5. Start the engine, Raise the RPM for one minute to purge the air from the system. Draining Contaminants 1. Tum off the engine and open the fiker vent. 2, Place a cup under the drain valve at the base of the Fuel Pro anc open the crain valve. 3. Water will low into the cup. When fuel begins to flow out of the drain, close the crain valve. (Drain the minimum amount of fuel possible.) 4. Close the filter vent. 5. Start the engine, Raise the RPM for one minute to purge the air from the system Suggested Preventive Maintenance Weekly ~ Every Filter Change ~ Change o-rings and grommet (included with new fiter) Every 12 Months ~ Check all electrical connections for conosion. Chock all fue! fitings for leaks, Drain water. Extreme winter or salt corrosion environments. may ‘require lubrication of the top colar threads with Loctite? 76747 antissize every 180 days.page 8 Ordering Information Housing = = Part Shs ee et ind Ce Cie i 7206, Wh Fresese | 89763 [2400 WA WA Fuautae | _Feo7es | WA WA Yes resus | F519763, NA WA Yes ruasoae | _f319763_| 1200 WA, Yes Fuasoat | _F519763_| 1200 NA, Yer oo nth ewzsoaz | stares | 24 v0 NA Ye tan rnee0as | F519769 | 120VAC NA Yes ry baer Lif Fuzgoaa | F610763_| 12 VOC WA Wa 7m Ts RighyOut Lt Fuzaoso | _F819763_| 24 VOC WA Wa Yes_| ie AignvOut Lat Fzgo54 | Fsi9703 | 12 voc. TROVAG WA WA [in AighsCut Lott Fuzg060___| _ FS19765 WA, WA WA Yes_[ in RighvOut at 23064 WA WA Wa Yes_[_ in RonsOut Lat P3067 00 24. V05 NA 7 Yes [in Righbut us F906" WA WA Yer _[ in RighvOut ca Wa Yes Yes_| in Aghybut ut F207 NA WA WA | inigtOut Let Fazsure ou--"| _FS19763 | Porsaviube | WA | Yesteonstanton | WA | inAntvOutLat Mt dagtae arieconaatone ef MES #1 ~ For Bots ove BS he oto REN pack ro ed pace he saad Gaskets tae proves wn ‘sera, 2880085. ‘fle Oi Fl reece ony Pus Sie opacaes tars, FreeereDpage 9 Specifications Height Ove 1615 (097 mn) Depth Dvr F725" (184 15 mm) Wen re Mount Bracke Oates 6a (75 me Fuet Connection (et) 274 NPT (2251.5) Fat Cannestion (Ore W214 NPTF (M22'«3.5) Fst Heat Connecion It) V2 NOTE (22 x15) Fst Heat Connection (Out 2 NPTE (WO? x15) Font Capacry (wer fesz aero) peatioe Fue Flow Rate 160 galt (661 Wie) Recommended Applestions Heavy Out Engines Wate Trap Capacty 98 Heri.) Fite Service Clearance Eccl Heater 1206, 250. 18238 2400, 250W, 11224 Y20VAG,75W, O65 A= 1 A Compatbe tor use win Diesel Fost Types Diese 42, Kerosene, Biodiesel, anaes Speciatare mibec cue winastnsten 1206660page 10 } Filtration Fiaserco (©2007 Cunyirs Fitration Prnteain ma USA For more information, please visit us at curnminsfitration.com