Davco fuel pro 382 Technical Manual Download Page 1 | Manualshive

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TABLE OF CONTENTS

Applications, Models, and Options . . . . . . . . . . . . . . . . . . 1
How it Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
“SEEING IS BELIEVING”

®

. . . . . . . . . . . . . . . . . . . . . . . . 2

Dimensions and Specifications . . . . . . . . . . . . . . . . . . . . . 3

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Important Safety Precautions . . . . . . . . . . . . . . . . . . . . 4

Installation Instructions  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 5
Installation Instructions - Diverter Cap  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 6
Coolant Heat Installation .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 7
12VDC and 24VDC Electric Pre-heater Installation   .  .  .  .  . 8
120VAC Electric Pre-heater Installation   .  .  .  .  .  .  .  .  .  .  .  .  .  . 9
Water in Fuel Sensor (WIF) Installation  .  .  .  .  .  .  .  .  .  .  .  .  .  . 10
Preventive Maintenance   .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 11
Filter Change Procedure  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 12
Visual Diagnostics With Clear Cover .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 13
Visual Diagnostics - Air vs . Vapor Bubbles .  .  .  .  .  .  .  .  .  .  . 14
Diagnostic Procedures - Air Leaks  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  15
Diagnostic Procedures - Heater Testing  .  .  .  .  .  .  .  .  .  .  .  .  . 16
Check Valve Diagnostics .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 18
Service Parts .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 19
Warranty Policy  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 23
Parts Return Policy  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 24

2016 ©DAVCO Technology, LLC .

October 3, 2016 11:34 AM

F1271 REV J

FOR UPDATED INFORMATION, VISIT WWW.DAVCO.COM

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Summary of Contents for fuel pro 382

Page 1: ...lation 8 120VAC Electric Pre heater Installation 9 Water in Fuel Sensor WIF Installation 10 Preventive Maintenance 11 Filter Change Procedure 12 Visual Diagnostics With Clear Cover 13 Visual Diagnostics Air vs Vapor Bubbles 14 Diagnostic Procedures Air Leaks 15 Diagnostic Procedures Heater Testing 16 Check Valve Diagnostics 18 Service Parts 19 Warranty Policy 23 Parts Return Policy 24 2016 DAVCO T...

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Page 3: ...fuel injection system Applications Heavy duty engines with fuel flow up to 180 GPH Cold Weather Solutions 12VDC Pre heater Uses igni tion switch to heat up fuel prior to running the engine 120VAC Overnight heater Pre vents gelling while parkedover night Coolant heat Keeps fuel heated while operating on highway Models and Options Base Model Unheated Coolant Heat Electric Pre heater Options Heat ers...

Page 4: ...ow with minimal restriction As the filter is used contami nants collect on the filter from the bottom up Fuel rises on the filter indicating remaining filter life Fuel level increases in clear cover As contaminants collect on the filter the fuel rises to a non contaminated section of the filter providing optimal filtration while maintaining lowest restriction Fuel level at filter wrap level Even t...

Page 5: ...ance Min 1 5 38 mm Max Fuel Flow 180 gph Electric Pre heater 12VDC 250 W 18 A 24VDC 250 W 12 A 120VAC 75 W 65 A Fluid Heat Connection 3 8 18 NPTF Filtration Performance at 100 GPH EST Micron Coarse Water Removal Emulsified Water Removal Dirt Holding Capacity grams 7 mic 99 4 80 5 70 10 mic 99 9 95 5 85 25 mic 99 6 97 8 110 50 mic 97 20 90 0 0 0 5 1 0 1 5 2 0 2 5 0 20 40 60 80 100 120 140 160 180 2...

Page 6: ...or mixtures in the area around the fuel source To elimi nate the potential for fire keep open flames sparks or other potential ignition sources away from the work area Do not smoke during filter replacement or service operations Inhalation Precaution Always perform engine or vehicle fuel system maintenance in a well ventilated area that is kept free of bystanders The ignition key must be in the of...

Page 7: ... hanging loops which can trap water Use 90 elbows only when necessary If the fuel hoses are cut to length on the job be sure that the inner liner of the fuel hose is not cut by the fit ting which can cause check valve performance issues Make sure hoses are clean and free of debris before installing To avoid damaging the aluminum Fuel Pro body do not overtighten fuel lines or fuel line fittings 1 R...

Page 8: ...the seal on the top of the diverter cap with clean engine oil 4 Thread the adapter onto the secondary filter stud and tighten 5 Install the Do Not Remove label on the diverter cap Diverter Cap Part Number Required Filter Head Stud Size Required Filter Head Seal ID Required Filter Head Seal OD 101480 1 14 2 475 2 895 101589 1 14 3 225 3 435 101570 M16 x 1 5 2 475 2 895 101466 3 4 16 2 475 2 895 101...

Page 9: ...Determine if the bottom plate is equipped with a fluid heat assembly Figure 3 If the Fuel Pro 382 has a deep bottom plate it is a heated assembly with a heater loop and can be upgraded to use coolant heat Refer to form F3029 on www davco com for upgrade instructions If the bottom plate is flat order the DAVCO fluid heat bot tom plate upgrade kit DAVCO P N 382029 23DAV Fluid heat bottom plate Flat ...

Page 10: ...ircuit will not handle a mini mum required current for the selected heater The following is a list of approved fuse ratings 12 VDC System 15 amp Fuse for a 150W heater 20 amp Fuse for a 155W PTC heater 25 amp Fuse for a 195W PTC heater 24 VDC System 10 amp Fuse for a 150W heater 15 amp Fuse for a 195W PTC heater 12VDC AND 24VDC ELECTRIC PRE HEATER INSTALLATION 85 30 51 87 86 12 24 VDC OPTIONAL REL...

Page 11: ...Pro to one inch below the top of the filter element Reinstall the vent cap Tighten the vent cap by hand until it clicks 6 Start the engine When the lubrication system reaches its nor mal operating pressure increase engine speed to high idle for one to two minutes To purge the air loosen the vent cap until the fuel level drops to just above the collar Tighten the vent cap by hand until it clicks No...

Page 12: ...lack ground lead with a 3 8 diameter loop end on the WIF wiring harness to the ground source near the Fuel Pro if applicable 8 Connect the green signal wire on WIF wiring harness to green signal wire on WIF indicator light Use additional green wire as needed 9 Locate 12VDC or 24VDC key controlled on power source Install a red wire from the power source to the red wire on WIF indicator light Add a ...

Page 13: ...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 service filter kit Every 12 months Check all electrical connections for corrosion Check all fuel fittings for leaks Seasonal Maintenance Extreme winter or salt corrosion environments may require lubrication of the collar threads with anti seiz...

Page 14: ...l it is seated on the body of the Fuel Pro and hand tighten the collar until it no longer spins freely Torque the cover assem bly by rotating the collar clockwise three additional ribs using the collar wrench 18 ft lbs 7 Prime the unit by filling the clear cover with clean diesel fuel until it reaches the top of the filter 8 Install the vent cap Tighten the vent cap by hand until it clicks 9 Start...

Page 15: ...ines from the fuel tank to the fuel processor Check lower and upper collar o rings Water is noticed in the cover Î ÎDrain the water If engine coolant is visible follow proper engine pressure testing procedures to determine root cause Fuel drains back to the fuel tank when changing the fuel filter or draining sepa rator Î ÎRemove the check valve assembly Clean or replace and retest Check air leaks ...

Page 16: ...tmospheric pressure in the fuel tank Vapor bubbles can vary from champagne size up to in diam eter They may increase in size or volume as engine rpm increases The lower pressure draws the entrained air vapor out of the fuel and these bubbles will be visible as the fuel exits the Fuel Pro See Figure 8 As the fuel enters the lift pump it is pressurized and the bubbles are compressed back into the fu...

Page 17: ...nd or check valve If the Fuel Pro is equipped with a pre heater do not remove the pre heater 3 Apply 15 PSI of air pressure at the fuel inlet Immerse the Fuel Pro in a tank of water and look for air bubbles 4 Correct the source of the air leak and retest B Bubbles Not Visible If there are symptoms of sucking air indicated by engine loping rough run ning performance power loss etc and there are no ...

Page 18: ... or less is recommended Current Flow Meter Clamp on type for DC current Ice dry ice CO2 or some means of chilling the thermo switch A flameless source of heat Infrared heat lamp etc a Vortex tube is a good tool to heat and cool for testing E E DO NOT USE a test light that has a wire probe for any of these tests If the insulation of the wiring is punctured moisture and road salt can penetrate into ...

Page 19: ...whether the pre heater resistance value is in the acceptable range Pre heater Watts Resistance Range ohms 12VDC two pin 250 W 0 6 to 0 8 77 F 25 C 12VDC single pin 250 W 0 6 to 0 8 77 F 25 C 12VDC single pin 150 W 0 8 to 1 1 77 F 25 C 12VDC two pin 150 W 0 8 to 1 1 77 F 25 C 24VDC two pin 250 W 2 to 2 5 77 F 25 C 24VDC single pin 250 W 1 8 to 2 3 77 F 25 C 24VDC single pin 150 W 3 6 to 4 1 77 F 25...

Page 20: ... 4 Inspect the check valve spring and spring retainer If the spring or spring retainer is broken or if the check ball has groves nicks or is out of round replace with a check valve service kit Otherwise clean and reassem ble the check valve assembly The spring retainer snaps into a groove in the check valve body 5 Replace the check valve assembly into the body and torque to 44 60 ft lb 6 Connect t...

Page 21: ...Kit includes vent cap o ring and collar o ring 102654 Check Valve Service Kit E ball spring and cage E F 103071DAV Check Valve Assembly F ball spring cage and body 380134 Metal Collar Wrench 102008 Drain Valve A C B D SERVICE PARTS FUEL PRO 382 TECHNICAL MANUAL T e c h n o l o g y L L C DAVCO Technology LLC P O Box 487 Saline MI 48176 Call 800 328 2611 www davco com F1271 REV J October 3 2016 11 3...

Page 22: ...is harness 102359 Chassis Harness Adapter Kit includes 12V Chassis Harness Adapter Weather Pack seals and plug A B 102376 Heater Chassis Harness Metri Pack Connector 102220 Heater Chassis Harness Weather Pack Connector Note Visit www davco com Form F1263 for 12v and 24V Pre heater part numbers for pre heaters installed prior to 2007 For Specific OEM numbers for pre heaters contact customer support...

Page 23: ... Thread 103111 2 Pin WIF with Tyco Connector 1 2 20 Thread Paccar 102600 WIF Chassis Harnerss Deutsch Connector Spin on Studs for use with emergency spin on filter 320628 Spin on stud 1 14 Silver Use Fleetguard filter FF105 with clear cover placed over filter E E for emergency use only 320620 Spin on stud 13 16 12 Yellow Zinc Use Fleetguard filter FF5333 with clear cover placed over filter E E for...

Page 24: ...2029 5SDAV Coolant Heat Ports 3 8 NPT 2 WIF Port 1 2 20 NPT Drain Port 1 2 NPT 382029NAV Navistar Bottom Plate application Coolant Heat Ports 9 16 18 NPT 2 Pre heater Ports 1 2 NPT 2 WIF Port 1 2 20 NPT Drain Port 1 2 NPT 382015SVC for Bottom Collar application Coolant Heat Ports 3 8 NPT 2 Pre heater Ports 1 2 NPT 2 Drain Port 1 2 NPT Unheated Bottom Plate Bolt On Heater Ports 1 2 NPT 382027SVCB P...

Page 25: ...ems and parts not manufactured or distributed by DAVCO Any aftermarket or OEM component not approved specifically to work with a DAVCO manufactured product Product that has been installed with aftermarket parts or altered or modified in any way Normal wear and tear abuse vandalism acts of God improper storage or handling disasters such as flood fire or war failure to operate maintain or repair in ...

Page 26: ...ccepted within 60 days from the date of purchase Proof of purchase will be required i e original invoice delivery receipt These types of return s are subject to a minimum restock fee of 40 or 40 00 whichever is higher Additional restock fees may apply Product s will be inspected for like new condition and additional costs will be the responsibility of the customer No obsolete parts may be returned...

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