Davco FUEL PRO 485 Technical Manual Download

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FUEL PRO

485

TECHNICAL MANUAL

F1485 REV B

T e c h n o l o g y , L L C

DAVCO Technology, LLC

www.davco.com

800-328-2611

1600 Woodland Drive, Saline, MI 48176-1629

•

Fuel from the tank enters the Fuel Processor body (suction side of the fuel system) .

•

Large contaminants and “free” water are 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 filter media and with lowest restriction .

•

Clean, water-free fuel exits the Fuel Processor and flows to the engine fuel module .

HOW IT WORKS

APPLICATIONS, MODELS, AND OPTIONS

FUEL TO FUEL TANK

FUEL TO ENGINE

ENGINE LIFT PUMP

FUEL FROM

FUEL TANK

Fuel System Diagram

Applications 2017 engine models

•

Detroit DD13, DD15, DD16

•

Cummins X15

•

New Cascadia

Meets/Exceeds 2017 engine manu-

facturer’s stringent water separation

requirements

Models and Options
•

Base Model - Unheated

•

Electric Pre-heater Options

•

12VDC PTC pre-heater

•

120 VAC Overnight heater

•

Water-in-Fuel (WIF) Sensor (standard

when used with Cummins X15 Engines)

Summary of Contents for FUEL PRO 485

Page 1: ...s 5 120VAC Overnight Heater Installation 6 Water in Fuel Sensor WIF Installation 6 12VDC 24VDC Pre heater Installation 7 Visual Diagnostics Air vs Vapor Bubbles 8 Visual Diagnostics with Clear Cover 9 Diagnostic Procedures Air Leaks 10 Diagnostic Procedures Check Valve and Heater Testing 11 Service Procedure Bypass Valve 12 Filter Change Procedure 13 Preventative Maintenance 14 Service Part Number...

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Page 3: ...intain a fuel path through the clean filter media and with lowest restriction Clean water free fuel exits the Fuel Processor and flows to the engine fuel module HOW IT WORKS APPLICATIONS MODELS AND OPTIONS FUEL TO FUEL TANK FUEL TO ENGINE ENGINE LIFT PUMP FUEL FROM FUEL TANK FUEL TANK Fuel System Diagram Applications 2017 engine models Detroit DD13 DD15 DD16 Cummins X15 New Cascadia Meets Exceeds ...

Page 4: ...ulsified 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 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 fil...

Page 5: ...11 62 in Weight Dry 10 35 lbs Fuel In Connection M22 x 15 6H Fuel Out Connection M22 x 15 6H Filter Service Clearance Min 5 5 in Max Fuel Flow 180 gph Electric Pre heater 12VDC 155W or 195W or 24VDC 195W Overnight heater 120VAC 75 W 65 A FILTRATION PERFORMANCE AT 174 GPH Micron 8 Coarse water removal 99 Emulsified water removal 93 Emulsified water removal end of life filter 80 Dirt holding capacit...

Page 6: ... Turn off the engine and remove the vent cap 2 Place a suitable container under the Diesel Pro and open the drain valve 3 Collected water will flow into the container When fuel begins to flow out the drain close the drain valve Drain the least amount of fuel as possible 4 Install the vent cap and tighten it by hand until it clicks 5 Start the engine and raise the RPM for one minute to purge the ai...

Page 7: ...triction observe the following guidelines when plumbing the fuel system Keep the fuel line routing as smooth as possible with no low 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 fitting which can cause check valve performance issues Make sure hoses are clean and fr...

Page 8: ...d thread sealant to the heater threads and install into the 120VAC overnight heater port on the Fuel Pro Tighten to 15 30 ft lbs 4 Connect the wire harness to the heater and route the harness to a location where it can easily be plugged into a 120VAC outlet 5 Prime the Fuel Pro and check for leaks 120VAC OVERNIGHT HEATER INSTALLATION WATER IN FUEL SENSOR WIF INSTALLATION 1 Open the vent cap Open t...

Page 9: ...uel Pro completely Close the drain valve 2 Remove the pipe plug in the heater port 3 Apply liquid thread sealant to the pre heater threads and install into the bottom plate 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 ignition switch The fuse rating depends on the pre heater installed 6 Prime the Fuel Pro ...

Page 10: ... the engine and check for bubbles If there are no air leak symptoms but bubbles are present in a sight tube at the fuel lift pump inlet they are most likely vapor bubbles Vapor Bubbles 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 because the pressure in...

Page 11: ...are seen flowing in with the fuel Î ÎCheck all fittings and lines from the fuel tank to the Fuel Processor Check lower and upper collar o rings Fuel drains back to the fuel tank when changing the fuel filter or draining separator Î ÎRemove the check valve assembly Clean or replace and retest Check air leaks in the fuel system Fuel level is at the top of the filter Low power Î ÎChange the filter at...

Page 12: ...n tact Use a DAVCO wrench if necessary to tighten the collar three additional ribs b If the drain valve is suspected install a plug in place of the drain valve for test purposes only 4 If air bubbles persist test as follows a Remove the Fuel Pro from the chassis b Plug the fuel outlet port Do not remove filter cover collar vent cap drain valve and or check valve If the Fuel Pro is equipped with a ...

Page 13: ...ing 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 reassemble the check valve assembly The spring retainer snaps into a groove in the check valve body 7 Replace the check valve assembly into the body and torque to 30 55 ft lb 8 Connect the fuel inlet hose using liquid or paste t...

Page 14: ... debris 6 Remove the bypass valve assembly and discard 7 Remove the protective cap from the replacement bypass valve assembly 8 Install the replacement bypass valve assembly into the Fuel Pro body torque to 20 ft lbs 9 Install the filter Refer to the section Filter Change to ensure that the filter is aligned correctly 10 Apply downward pressure on the top of the cover and rotate the collar until c...

Page 15: ...en the collar 4 Remove the clear cover and collar from the Fuel Pro Discard the cover o ring and install a new o ring sup plied with the filter on the cover Clean the threads on the collar and the body 5 Install the new o ring on vent cap supplied with the filter 6 Remove the filter element by pulling upward 7 Install the new filter element Position the filter element so the key is lined up with t...

Page 16: ...ntil it clicks Preventative Maintenance Weekly Drain water 1 Turn off the engine and open the vent cap 2 Place a suitable eight ounce plastic or metal container under the drain valve at the base of the Fuel Pro 3 Turn the drain valve one to one and a half revolutions to open the drain valve 4 Water will flow into the container When fuel begins to flow out the drain close the drain valve Drain the ...

Page 17: ... DVC 101132 Check Valve Service Kit P N DVC 101132 Check Valve Body Check Valve Assembly with body P N DVC 482012 J Plug DVC 020909 K see next page PTC Pre heater 12V 155W Metri Pack DVC 103594DAV PTC Pre heater 12V 195W Metri Pack DVC 103528 PTC Pre heater 24V 195W Weather Pack DVC 102692 L Quick Connect Drain Valve Includes valve body retaining ring M both seals N drain valve and protective cap ...

Page 18: ...1629 SERVICE PART NUMBERS PART NUMBER DESCRIPTION DVC102145 120VAC 75W Overnight heater DVC103528 12VDC 195W PTC Pre heater Metri Pack Harness Length 19 5 inches DVC103594 12VDC 155W PTC Pre heater Metri Pack Harness Length 19 5 inches DVC 102692 24VDC 195W PTC Pre heater Weather Pack Harness Length 18 5 inches DVC 102770 WIF Metri Pack Harness Length 6 5 ...

Page 19: ...e loss of profits or income loss of capital cost of substitute 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 distributed by DAVCO Any aftermarket or OEM component not approved specifically to work with a DAVCO manufactured product Product that has been i...

Page 20: ...issued for returns 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 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 Additio...

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