Fleelquard Diesel Pro® FH235 and FH236 Series Filter/Separator/Warmer Installation Instructions Diesel Pro® 235 Parts List 4 Peco r ba = A. [Ca Vent Cap 0-Ang, Coir. Cover, 3073506 $ ~. Cova are Sis) Biesel O-Ring Fook oy ® » [eemucetrnactn | spas -Rina Pack tsp Agar ove’ Fr) vein | CaS Sacre” [Te rmereener ame ve | creck vavessery mrs Som one a e031 i [Mee 784 MIG 15 ‘3973689 5 = aca 78-149 00 NT ‘nona0e § sedan Vahe © © ® + 4. CAUTION: These inetructons are intended for uae by profeaonalmachanon who ae rained she proper 1S comer ts, ens sepia tay erecace poasene yo snoeainepage 2 vertcaporeng, 8005 Parts List = rete Ve 1n- |cap vettaporing, Gta, co, | saatass Cover O-ieg and Song) iottese O-Ring Pack — ony 18 | rigor >B5 thal freaes ont sosotse § (Cap O-Ring anc caver Org) [iter ferent ET 1D | check Vane Asomty 2072200 § | ies Pi F706. 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Screws, | 9072255 8 Drain te 0-Fing an ran Vv) Tr [nae hater oae cars Sa tea 4 | Applications foptional) ‘season S Tea [wr wg es eee | soon [wr sos070s Pail aemiiiea oaiaar Oy “W_| Maneal Primer Pump Chace aire arms ai aa Te - | Manual Primer Purro (M76) 3978203 S Manual Primer Pump Mw © ® gopages Introduction * Fuel from the tank enters the Diesel Pro® body (suction side of the fuel system) + Large contaminants and “tree” water aro Separated from the fuel and remain in the body. * Fuel rises into the clear cover. ‘+ Contaminants and emulsified water are captured by the filter media. © Fuel level rises to maintain a fuel path ‘through the clean fiter media and with lowest restriction, * Clean, water-free fuel exts the Diesel Pro and flows to the lift pump. “Seeing Is Believing” * See when NOT to change the fuey Nite. ‘+ See the condition of the tual. Seeing what collects on the fter media or what's happening inside the clear cover can help diagnose many fuel and mechanical conaiitions. + “Filter on Tep” configuration, Water and debris removed trom the fuel falls to the lower chamber and stays away from the fter media resulting in longer filter if. * Built-in protection when priming the fuel fitor. Unfiltered fuel fs kept on the “dirty” side of the {iter media during priming ensuring only clean tue! reaches the engine + Patenteci media. The “Best in Class" StrataPore™ media removes 95% of free and emulsified water. This performance far exceeds that of cellulosa media 4 Figure 1 - “Seeing |s Believing” When new, the fuel level in the filter will be very low with minimal restriction. As the fiter is used, contaminants collect on the fiter from the bottom up. Fuel rises on the filter indicating remaining fiter life. Fuel level increases in clear cover. As contaminants collect on the fiter, the fuel rises {0 a non-contaminated section of the titer, providing optimal fitration while maintaining lowest restriction Fuel level at filter wrap level. Even though the fuel level is now more than half of the fiter ‘element, the {ual is stil flowing through clean ‘media at minimal restriction levels. The fiter still hhas significant life remaining. ‘The filter element is now completely covered by fuel. At this point, all of the media's surface area is utlized. Restriction is increasing and the fiter element should be changed at the next scheduled maintenance interval.page 4 Service Kit Installation ‘This system must be installed between the fuel ‘tank and the transfer fuel pump. If approved by the manutacturer this system can be used as the only ‘uel fiter in the fuel system by removing the existing filter and heads, or by removing the fiters only and replacing them with special Divertar Caps (sold ‘separately - see Table 1). Note: If the Diesel Pro® is used as the primary filter and a secondary filter is required, secondary filter life may be extended. Table 1 - Diverter Gaps eer See ret ied) ed 22501916) 2aP5 (62865) verter Cap Required Fiter etree certs wibxTS 4. WARNING: When diese! fuel is circulated ‘through an operating engine, it ‘can become very hot. To prevent personal injury: A Sealding hazard! 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. Fire hazard! Heated diesel fuel can form ‘combustible vapor mixtures in the area around the fuel source. To eliminate the potential for fire, keep open flames, sparks or other potential ignition sources away from the work area, and co not smoke during fitter replacement or service operations which could result in the escape of diesel fuel or fuel vapors. 2 Inhalation hazard! Always perform engine or vessel fuel system maintenance ina well ventilated area that is kept free of bystanders, & The ignition key must be in the OFF position. Installing the Diesel Pro Service Kit 1. With the engine shut down end at ambient temperature, close the fuel shutoff valve (f equipped) and place a suitable container under the fuel fiers. 2. Remove the primary fuel fter element ascombiy, sedimenter, and/or water separator. Drain the used element and dispose of it in an environmentally responsible manner, according to state and/or federal (EPA) or national recommendations. The fuel can be retumed to the tank 3. For a one-fiter system, select the required secondary fer head diverter cap trom those ited in Table 1. The required part number is determined by the size of the spin-on filter stud {and the fiter sealing surface ciemeter. Install the diverter cap on the secondary titer head es follows a, Remove the secondary fuel filter element, drain and dispose of it in an environmentally responsible manner according 10 government regulations (ie., state/province, federal, etc.) ‘The fual can be retumed to the tank, bb. Lightly lubricate the seal on the top of the diverter cap with clean engine oil G, Thread the adapter onto the secondary titer stud and tighten by hand only. 4. Iestall the “Do Not Remave" sticker on the diverter cap. 4. Mount the Diese! Pro in the desired location using 3/8" (2.5 mm) Grace 8 haraware. Keep the following points in mind: . Mounting the Diesel Pro directly on the ‘engine is NOT RECOMMENDED. b. Mount vertically with the cover and element pointing up. ¢. Make sure there is enough top and side Clearance for the cover to be conveniently removed ‘or fliter replacement (5° G8.1 mm) mamum). 4d. Bolt spacing is 5.25" (133.35 mm). AX CAUTION: The Diese! Pro” MUST be installed 0 that the Filter Element is above the "FULL" lovel of the fuel tank. Hf mounted below full tank level, 2 shut off valve will be required at the inlet to allow filter changes. without overfiow of fuel.— page 5 ‘8. Route the fuel supply ine as follows (see Figure 2): ‘a, Route the fuel suppiy line from the pick- Up on the fuel tank to the Diesel Pro inlet (labeled “Fue’ In’). . Route the fue! outtat ine from the Diesel Pro Outlet (abeled “Fuel Out") the inlet of the fuel pump. Figure 2 ~ Diesel Pro Connections Noto: Tho inlet and outie fitings can be moved from side to side depending on the appication. For example, in Figure 3 the FUEL IN is on the right anc the FUEL OUT 15 on the rht, Be sure 10 use only ONE INLET and ONE OUTLET por per installation. (Tighten adapter fittings and plugs to 25-40 ftoibs (2.6-4.6 N-m}) Figure 3 - Fusi Line inlets and Qutiets 6. To minimize restrictions, observe the following guidelines when piumibing the system. Keep the fue! line routing as smooth as Possible with no low hanging loops which can trap water b. Use 90° elbows only when necessary. . Ifthe fuel hoses are made up to length on the job, be sure that the inner liner of the fuel hose is not cut by the fitting, creating Potential check valve effects. Also make sure hoses are clean and free of debris boforeinstaling 4S CAUTION: To avoid damaging the aluminum fuel processor body, do not ‘vertighten fuel lines or fuel line fittings. 7. len electrical heater is required, see page 6, Installing an Optional Electric Heater. Installing a WIF (Water In Fuel) Probe 1. Remove the 1/2°-20 WIF plug trom the bottom of the Diesel Pro. 2. Install the WIF Probe (9911940 8) into the bottom af the Diasel Pro (see Figure 4), Torque to 20-24 in-ibs (2.3-2,8 Nm). 3. Install the WIF wiring hamess (3850729 5) on the WIF Probe. The hamess has the following ‘connections: black ground lead with a 3/8" (8.59 mm) diameter loop end and a green WIF wire. ) Figure 4 ~ WIF rote Installation 4. Drll.a 1/2" (12.70 mm) nole in the dash or control panel where the WIF LED (9948670 S) is to be located, a. Installation must have 1.5° 8.10 mm) of Clearance behind dash or contro! panel. Use caution not to damage nearby ‘components when driling, 5. Connect the biack ground wire on WIF LED toa ground source. Attach additional black wire as needed.page 6 6. Insta WIF LED by pressing firmly into the dalled hole. 7. Connect the black ground lead with a 3/5" (G.53 mm] diameter loop ond on the WIF wiring ames to ground source near the Diesel Pro (feppicable). 8. Connect green signal wire on WIF wiring harness to 4" (101.60 mm) green signal wiro on WIF LED. Use adoitional green wire as needed. 8. Locate 12 VDC oF 24 VDC power source. Run a red wire from power source to the red wite on WIF LED. Add 1 A inline fuse (not inctuded) (See Figure 5). ‘Ground Figure 5 = WIF Wiring Note: Use appropriate connectors to attach the wires. To test the WIF incicator, pour water Into the body of the Tuel processor unti it ‘covers the WIF probe. The WiF LED should Huminate. Installing an Optional Electric Heater Al units come with pre-driled ports to allow for heaters/thermostats, The electric heaters available for the Diesel Pro® are 12 or 24 VDC Combo Thermo/Heeters and 120 VAG Heater. Eieciric heaters are optional and must be ordered separately (see Tape 2). 24 ¥0G. 180W Cone TreraaAent Han Electric Heater is not areagy installed. remove the 7/8"-14 SAE (M16 x 1.5) o-ring heater plug ftom the Diesel Pro and install the Heater. Torque to 25-40 ft-lbs (2.8-4.6 N-m). (See Figure 6) Figure 6 - Heater Instalation Connect the Chassis hamess to the Diese! Pro hamess. ‘Attach the grouncing eyelet to the chassis using a sutatle 9/8" (9.5 mm) bolt. Connect the Power Lead to the accessory side Of the ignttion switch. (Use of a 15 A fuse is recommended, but nat included in the Diesel Pro kits. Use a relay if the ignition circuit will not handle a minimum of 15 A) (See Figure 7.) Figure 7 ~ Fuse and Relay Connectionspage 7 Installing Optional Priming Pumps ‘The Fleetquard® Manual Priming Pump must be installed on the suction sds of the fuel system. A. CAUTION: Do not over tighten the fuel hoses: to the fittings to avoid damage to the Priming Pump or filter housing. Installing with a New Diesel Pro” Produced Before August 30, 2010. 4. Disconnect the fuel inlet line coming from the fuel tank 10 the Diesel Pro inlet. 2. Thvead the “T" shaped plunger pump from kit #9979202 § (M18) or 3079203 5 (M16) into the Fu! niet Port of the Diese! Pro. 3. Attach the fuel line trom the fuel tank to the iniat of the Primer Pump. Tighten to 25-40 t-1b (39,9-54.3 Nem) of torque. Remove the vent cap from the Diesel Pro. ‘Cycle the plunger of the Priming Pump unt the Diesel Pro is full of fuel. 7. Hand tighten the vent cap. 8. Start the engine. When the lubrication system reaches normal operating pressure, increase the RPM for one minute. Slowly open the vent cap Until the fue! level drops to one inch above the collar. 9, Chock for fusl leaks, pas 410. Installation is complete. Figure 8 - Installing the Priming Pump with # Diesel Pro Produced Before August 39, 2010 Installing with a New Diesel Pro® Produced ‘After August 30, 2010. With the engine shut down and at ambient temperature, ciose the fuel shut-off valve (i equipped) and place a suitable container under tho, Diesel Pro and drain the tue! until empty. 4.Disconnect the fuel inlet line coming from the fuel tank to the Diesel Pro inlet, 2. Thread the Check Valve trom kit 9975110 into the inlet port of the Diesel Pro. 3. Reconnect the fual line from the fuel tank to the Diese! Pro inlet with Check Vaive in place. 4 Remove the plug from the free Fuel Inlet Port. 5, ‘Thread the Plunger Assembly from kit 39751108, into the tree Fue! infet Port 6. Tighten to 25-40 ft-lb (29.9-54.3 N-m) of torque. 7. Remove the vent cap rom the Diesel Pro, 8. Cycle the plunger of the Priming Pump until the Diesel Pros full of fu 9. Hand tighten the vert cap. 40, Start the engine. When the lubrication system teaches normal operating pressure, increase the Revolutions Per Minute (RPM) for one minute. Slowly open the vent cap until the fuel level ‘drops to one inch above the collar. 414. Check for fuel leaks. 12. installation is completa Figure 9 ~ Instaling the Priming Purp with a Diese! Pro Produced After August 30, 2010pages Filter Change Procedure 1. Remove the vent cap and open the drain valve to drain the fuel below the colar level. 2. Remove the collar using the Collar/Vent Cap Wrench (9944458 S) then remove the lear cover. = J Figure 10 - Collar/Vent Cap Wrench 3. Remove the fiter, cover, and vent cap seals. Dispose of the fiter and the seals property. 4. Using a clean rag, clean the cover, the collar, and threads on the Diesel Pro® body. 5. Install a new fiter, cover seal, and vent cap seal, 6. Reinstall te clear cover and collar. Hand tighton the collar. 7. Prime the unit by filing the clear cover with clean diesel fuel until it reaches the top of the fiter. 8. Install the vent cap. Hand tighten only. 9. Start the engine and run for one minute. Slowly open the vent cap and allow the tual to drop to about one inch (82 mm) above the collar. 10. Giose the vent cap. Hand tighten only. itis ‘normal for the fu! level to vary after the initial start-up and during engine operation. Fiter performance is not atfected. Table 3 - Replacement Filters ~ Diese! Pro® 235 Priming the System ‘The Diesel Pro fuel processor must be fled with clean fuel before the fitering system wil operate Property. Lise the following procedure to prepare the Diesel Pro for service. 1. Chock to make sure the drain valve at the base of the Diesel Pro is closed, 2. Remove the vent cap trom tne top of the Clear cover. 3. Fillthe Diesel Pro fll of clean fuel. 4, Reinstal the vent cap and tighten by hand only. 5. Start me engine. 6. When the lubrication system reaches its normal ‘operating pressure, increase engine RPM to high idle for one to two minutes. After the airs purged, loosen the vent cap until tne fuel level lowers to just above the collar Retighten the vant cap by hand only. 7. Hand tighten the collar again while the engine is running. AX CAUTION To avoid damage, do not use tools to tighten the coll Note: The clear fier cover will not fil completely during engine operation. It wil gradually fll ver time and the fue level wil rise as the filter becomes plugged,page 9 ‘Suggested Preventive Maintenance Weekly — Drain water 4. Tum off the engine and open the vent cap. 2. Place a suttable eicht ounce plastic or metal ‘container under the drain vaive at the base of the Diesel Pro and open the valve. 8. Water will low into the container. When the fuel begins to flow out the drain, close tha drain ‘valve. Drain the least arrount of uel possible. 4. Hand tighten the vent cap. 5. Start the engine. Raise the RPM for one minute to purge the air from the system. Every Filter Change ~ Change the cover and vent Cap O-rings (included with the fitter service kit). Every 12 Months ~ Check all electrical connections ‘or carrasion. Check all fue! fittings for leaks, Extreme winter or salt corrosion environments may require lubrication of the top collar threads ‘with Loctite® 76747 anti-seize every 180 days. Perici tg Coan Ua aeeat Remove the vent cap and open the drain valve, drain the Diesel Pro® completely. 2. Remove the collar, then remove the clear cover. 3. Remove the titer, cover and vent cap seals. Dispose of fters and seals properly. 4. Using a clean shop rag, clean the caver, the Collar and threads on the Diesel Pro bocy. 5. Remove the check vaive assembly (see Figure 11) Figure 11 = Removing the Check Valve Assembly 6. Clean and inspect the check valve body (Replace i the valve or the seat show any visibie signs of damage) 7, Replace the check vaive assembly into the Desel Pro body torque to 12-14 ft-lbs). 8. Install a new titer, cover seal and vent cap seal ‘8. Reinstall the clear cover and collar. Tighten the collar. 10, Prime the Diesel Pro by filing the clear cover with clean diesel fue! until it reaches the top of the filter. 11. Instal the vent cap. 12. Star the engine and run for one minute. Sowly ‘open the vant cap and allow the fuel level to drop to about one inch above the collar. 18. Close the vent cap. Hand tighten oniy. Troubleshooting Every Diesel Pro is factory tasted for leaks and is ‘marked with a traceable number to show that it has assed production testing, Most fled issues associated with leaks are related to loose fittings. These leaks are easily eliminated by checking and torquing the fue! fittings in the area of the leek, ‘Some fittings may also recuire the application of liquid Tefion® sealer. Note: All suction side fuel filters experience bubbles. Itis normal to see champagne size Dubbies in the Diesel Pro at the Diesai Pro outlet or at the lift pump.Page 10 ‘Air Leak Air bubbles wil be visible in the clear cover of the Diesel Pro ifthe leak originates from the fuel tank up to the fue! filler. The following is a quick test to Isolate the air leak source. Bubbles Visible: 1. Remove the Diesel Pro iniet hose. Install a jumper hose from the Diesel Pro to the fual tank (through the fil cap) orto a container of fuel 3. Start the engine. I this eliminates the air bubbles, the air source is at the fuel tank fittings ‘or hose connections. 4. Tighten all fitings and connectors 5. Retest If air bubbles persist, the air source is on the 01 Pra side of the system: 41. Tighten all fittings on the Deese! Pro. 2. Tighten the collar. ‘3. Ifthe drain vaive Is suspected, install a plug in place of the drain valve (for test purposes only). If air bubbles continue to persist, test as follows: 1. Remove the Diesel Pro from the chassis. 2. Plug the fuel inlet port. Do not remove filter, ‘cover/collar, vent cap, drain valve and/or check valve. If the Diesel Pro is equipped with a Preheater, do not remove the preheater. 3. Apply 15 PSI of air pressure at the fuel outlet. Immerse the Diesel Projin a tank of water and look for air bubbles 4. Correct the souree of the air leak and retest. Bubbles Not Visible 1. tere are symptoms of sucking ar (indicated by engne lopingirough running pertormanco/ power loss, etc)) and there are no bubbles in the Clear cover, the air leek is elther at the Diesel Pro ‘outet fitting, vent cap o-ring, the lft pump inlot Connection, or the fuel hose/connections to the itt pump. 2. Inspect and tighten fittings as needed. Excessive Restriction If the fuel lavel is at the top of the fiter, replace the fuel titer, The Diese! Pro will not cause excess system restriction if the fuel level is below the top of the iter. Loss of Prime When air is introduced into the fuel system, (for example, when draining water from the Diese! Pro ‘or when replacing the fuel filter) a check valve is, needed to keep the fuel system primed trom the Diesel Pro back to the fuel tank. A check valve is standard with all Diesel Pros. To test for proper check valve operation: Romave the fuel iniet hose and open the vent cap. Fue! should not flow out of the Diese! Pro, although a slight seepage of fuel is normal. If fual drains back to the fuel tank, remave the check Valve assembly: 1. Disassemble the check valve assembly. Clean ana inspect. 2. Replace the assembly if any cuts, grooves or nicks are evident In the valve or valve seat. ‘3. Reinstall the check velve assembly.page 11 Peer er ee iis cee 74700, 100 zvoc, 180W |W F260 Mi Fevo7as wa Ye, 7av0. 10, alzlz|z|e|s|2|2|3| WA In Agta Lat 23601 rises | v2voc wow | wa Rg | __TOTI SAE F23602 rstseea | avoc.1sow | WA Tnngibttan | Tara cAE FAz3600 Fsuar2e wa | vee Ta RghOut a izag04 Wi Fsiara8 WA | Yes Fazse0s NE Fstarze | eavoc. ow | vee 23606 WM Fsiaree | 24v0c. 20" | Yes avo OW Tangier Lah Fad Wt Fsvaree | (200.2500 | ves Ta RhVOut at FH73525 Fstares | 2avoc.2sow | Yes razsez7 Fsi9728 WAL Yes TARO at + netavaiaten Bizc98 "Note The Del Pro 235 cane urate to 1 Dasa! Po 238 by relate coe ith Foe rt rare 373808 Sar he fier wh Festouars part mumer FSS96R. Fr more nian ona: Feat Citas Aasetaonpage 12 se 473 mm) Fal Capac wa Mit ser a0 ea CS.0 et bet Barney isch ie hor ve Cas so aazan Seman Wag ESTE Tetezerig Fat oe rem reson rare we 15) 702 er 995 A) Mourtrg Brace aa] T2OO, c0W.TESA=I9A 24 VOC. 150 W. 634208 part Fut ow Rate so oath 041 Um Reconrended Aapiealons ust ane Woakon Day Eapbes ent ana Madr Duty Eins Wt Tap Capel 78261 669 nb 152 oe ASO) Fier Servce Ceara in 15 Mia 15.1 fravoc 130, 2SA=13A 2avoc 150W,63A=054 fein [24 0c, 250,241.04 | 24V0C 250, 10442108 T2OVAE 75W.OSSA=006A | 120VAG,T5W.064A= DOOA Rates [comput ruse with esl, Dee 2 Keren, Bisel ond JP Sorefeatont sibect 9 dango witout ratio= Dimensions Diesel Pro? 235 g F1215FGD € Filtration For more information, Wait ‘cumminsfiltration.com