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FUEL PRO

®

 483

TECHNICAL MANUAL

T e c h n o l o g y ,   L L C

7

DAVCO Technology, LLC       P. O. Box 487        Saline, MI  48176         800-328-2611      www.davco.com     F1305 REV F

Note: 

Steps 1 thru 4 can be skipped if the Fuel Pro 483 

coolant heat ports are easily accessible .
1 .  Remove the vent cap and drain the Fuel Pro complete-

ly .

2 .  Disconnect the fuel inlet and outlet hoses .
3 .  Disconnect all electrical components (if equipped) .
4 .  Remove the Fuel Pro from the truck and mount in a vise 

so the Coolant Heater Integral Manifold area is acces-
sible .

5 .  Remove the Thermovalve plug using a 1¼" socket or 

wrench and discard . 

Note: 

To identify if your Fuel Pro 483 has a thermovalve 

installed, the thermovalve plug will be gold in color .
6 .  Install the Thermovalve assembly with the brass sens-

ing probe first . Be careful to guide the Thermovalve into 
the port straight without damaging the o-rings .  

7 .  Torque to 30-55 ft-lbs .
8 .  Remove a ½" NPT steel plug from each side/bottom of 

the Coolant Heater Integral Manifold . 

 

CAUTION: A coolant shutoff valve is required 
for summer operation for most engines, 
until the DAVCO Thermovalve is available. 
A shutoff valve can be installed in either of 
the coolant ports in the Fuel Pro 483 or the 
coolant hoses going to these ports.

9 .  The ports are available on the bottom and side of the 

Coolant Heater Integral Manifold for ideal fitting clear-
ance per application . Only one port per side can be 
used to ensure ample coolant flow across the body . 
Coolant flow is not direction sensitive .

Note: 

 Do not connect as shown below .

10 .  Select suitable ½" NPT to 5/8" barb fittings – straights, 

45°s or 90°s can be used, based upon application 
requirements .

11 .  Apply liquid thread sealant to the threads of the fittings .

Note: 

Do not apply sealant to the first two threads of the fit-

ting . This is to prevent excess sealant from getting into the 
coolant cavity of the Fuel Pro .
12 .  Install the fittings and torque to 15-30 ft-lbs . Position 

the fittings as needed .

13 .  Install the Fuel Pro 483 and torque the mounting hard-

ware to OEM specifications .

14 .  Connect the electrical components .
15 .  Connect the fuel inlet and outlet hoses .
16 .  Connect a hose from the high pressure side of the 

engine coolant system to the Fuel Pro Coolant Heater 
Integral Manifold .

 

Coolant lines must be parallel, not in series.

17 .  Connect a hose from the Coolant Heater Integral Mani-

fold to a low pressure side in the coolant system .

Note: 

“Y” or “T” connectors can be used in the cab heater 

hoses if no engine ports are available .
18 .  Prime the unit by filling the clear cover with clean diesel 

fuel until it reaches the top of the filter .

19 .  Install the vent cap . Tighten it by hand until it clicks . 
20 .  Start the engine and run for one minute . 

Slowly 

open 

the vent cap and allow the fuel to drop to about one 
inch above the collar . 

21 .  Close the vent cap . Tighten it by hand until it clicks . 

Note: 

It is normal for the fuel level to vary after the initial 

start-up and during engine operation . Filter performance is 
not affected .

UPGRADING FUEL PRO 483 TO COOLANT HEAT*

Summary of Contents for FUEL PRO 483

Page 1: ...cations 3 Important Safety Precautions 4 Mounting and Fuel Line Routing 5 Coolant Hose Routing 6 Upgrading Fuel Pro 483 to Coolant Heat 7 12VDC Electric Pre heater Installation 8 120VAC Electric Overn...

Page 2: ...r cover Contaminants and emulsified water are captured by the filter media Fuel level rises to maintain a fuel path through the clean filter media and with lowest restriction Clean water free fuel exi...

Page 3: ...water over the life of the filter This far exceeds the performance of cellulose media SEEING IS BELIEVING When new the fuel level in the filter will be very low with minimal restriction As the filter...

Page 4: ...earance Min 3 5 in 88 9 mm Max Fuel Flow 180 gph Electric Pre heater 12VDC 195 W 18 A 120VAC 75 W 65 A Filtration Performance at 100 GPH EST Micron Coarse Water Removal Emulsified Water Removal Dirt H...

Page 5: ...he fuel filter or performing service operations which could result in spillage of fuel from the fuel system Fire Prevention Heated fuel can form combustible vapor mixtures in the area around the fuel...

Page 6: ...f equipped and place a suitable container under the fuel filters 2 Remove the primary fuel filter element assembly sedi menter and or water separator Drain the used element and dispose of it in an env...

Page 7: ...ttom of the Fuel Pro 483 and a low pressure hose on the op posite side or bottom Figure 1 Note Coolant hoses must be connected so the coolant flows completely though the Coolant Heater Integral Mani f...

Page 8: ...ure ample coolant flow across the body Coolant flow is not direction sensitive Note Do not connect as shown below 10 Select suitable NPT to 5 8 barb fittings straights 45 s or 90 s can be used based u...

Page 9: ...to the pre heater threads and install into the Fuel Pro base Tighten to 15 30 ft lbs 4 Connect the chassis harness to the Fuel Pro harness 5 Connect the power lead to the fused accessory side of the...

Page 10: ...available on the right side 120VAC Heater Port 12VDC Heater Port 1 Drain all the fuel from the Fuel Pro The fuel can be reused after the heater is installed If the fuel is not reused dispose of it in...

Page 11: ...to the ground source near the Fuel Pro if applicable 9 Connect the green signal wire on WIF wiring harness to green signal wire on WIF indicator light Use additional green wire as needed 10 Locate 12...

Page 12: ...t the drain close the drain valve Drain the least amount of fuel as possible Close the vent cap Tighten it by hand until it clicks Start the engine Raise the RPM for one minute to purge the air from t...

Page 13: ...e the unit by filling the clear cover with clean diesel fuel until it reaches the top of the filter 8 Install the vent cap and hand tighten until it clicks Start the engine and run for one minute Slow...

Page 14: ...s All diesel fuel has some level of entrained air caused by the natural splashing that occurs in the fuel tank during normal vehicle or equipment operation Vapor bubbles develop in the Fuel Pro becaus...

Page 15: ...es continue to persist test as follows 1 Remove the Fuel Pro 483 from the chassis 2 Plug fuel outlet port Do not remove filter cover collar vent cap drain valve and or check valve If the Fuel Pro 483...

Page 16: ...e harness 2 Connect the ohm meter leads to the pins of the pre heater For heaters with one pin connect to the pin and the bushing Use the following to determine whether the pre heater resistance value...

Page 17: ...embly with body 1 2 14NPTF 103071DAV Collar 482003SDAV Cover Assembly Cover and O ring 483047SDAV Drain Valve 102008 Spring 380056 Filter Refer to Filter Matrix F3105 www davco com parts html Check Va...

Page 18: ...E HEATER PART NUMBERS Description Part Number 120VAC Overnight heater 75W 120V 102145 12VDC Pre heater Metri Pack 195W 12V 103528 12VDC Pre heater Weather Pack 195W 12V 103529 WIF Deutsch Connector gr...

Page 19: ...te equipment living expenses claims by purchaser s customers or other third parties or other incidental special or consequential damages Attachments accessory items and parts not manufactured or distr...

Page 20: ...rns in which DAVCO inadvertently shipped incorrect quantity or product Overstock Returns for ordering more product s than required or incorrect part s will be accepted within 60 days from the date of...

Page 21: ......

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