Fass FA D10 220G Installation Manual Download Page 1 | Manualshive

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INSTALLATION MANUAL

APPLICATION:

FA D10 220G (220GPH @ 45psi)

FA D10 240G (240GPH @ 45PSI)

Cummins 5.9L 12 Valve

*with P7100 Injection pump*

**bypassing the factory lift pump**

1994-1998

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Summary of Contents for FA D10 220G

Page 1: ...INSTALLATION MANUAL APPLICATION FA D10 220G 220GPH 45psi FA D10 240G 240GPH 45PSI Cummins 5 9L 12 Valve with P7100 Injection pump bypassing the factory lift pump 1994 1998 ...

Page 2: ... support to our network of dealers so our customers needs and expectations will be exceeded To help insure you receive the proper system and customer support at the local level FASS has a VIP and Authorized Dealer network representing FASS products This is one reason you must purchase through a dealer to comply with our warranty policies If you do not there is no warranty We recommend you go to ww...

Page 3: ...ions concerning the electrical system before at tempting any electrical connections Be sure that the serial on this installation manual matches that of the outside of the box Flush and clean all brass fittings and fuel line from debris Keep debris from entering the internals of the system during installation Getting debris in the T port can lock up the motor If the motor does lock up from debris c...

Page 4: ...esults in accuracy and efficiency due to training communication and our relationship with our dealer network we recommend a ViP FASS dealer for the installation They are prepared to install the FASS fuel pumps with the most effi ciency If a situation problem arises during the installation they are the most pre pared for that situation problem DPPI is not responsible for any installation mis takes ...

Page 5: ...el filter life and to prevent engine damage E To Engine T Fuel Inlet Port Boost Compensation Port Adjustment Lock Nut Set screw Fuel Pressure Port Installation Step 1 Install Electrical Harness Step 2 Prepare Suction Line Step 3 Mount Fuel System Step 4 Install Fuel Line Step 5 Check Set Pressure Step 6 Check Installation ...

Page 6: ...Contents FL 1002 x14 WH 1005 MP 9037 BHB 1001 THB 1001 FF 3248 FPB 2005 ...

Page 7: ...0 PL 1005 Ring Terminal BHF 1002 PL 1004 ST 1005Px16 BHN 1001 OR 223 LW 1001 DIPF 1003 RS 1002 1 2 Plug PL 2003 Cable Ties 46044 Mounting Package Contents 4 1 4 20x1 75 1 4 Nut 1 4 washer 2 1 4 20x1 5 RS 2001 46260 ...

Page 8: ...plied to prevent corrosion FUSE RELAY The installation of the electrical harness is done first allowing power to be applied to the pump for lubrication purposes later in the installation A Using wire stripping tool remove excess insulation off the add a fuse and the WH 1005 B Place wire from 46044 and WH 1005 into butt connector Using crimping tool connect 46044 and WH 1005 with butt connector Ins...

Page 9: ...pan el G Route WH 1005 wire harness along frame rail to mounting location of pump Completion of this step will be addressed in the Mounting Step 3 F Locate fuse box under hood and select ignition hot fuse Remove fuse and put Add A Fuse in place Install fuse previously removed The use of a corrosion preventative on electrical connections is recommended ...

Page 10: ...rflow tubes from the truck by loosening the clamps at both ends A Very Important Before removing the fuel tank identify ALL areas of clearance between the tank and bed to install the draw tube assembly The closer the suction tube is placed to the center of the fuel tank front to back and left to right the more usable fuel there will be NOTE Hose clamps are not recommended for push lock fittings Th...

Page 11: ...btained place the assembly into the drilled hole securing the assembly using the lock washer nut Tighten Nut Loctite may be applied to the threads of the BHF 1002 for added insur J Drill a 1 3 8 hole catching all debris De bur hole and remove any missed debris in the fuel tank K VERY IMPORTANT Support fuel tank on both ends allowing the nat ural formation of the tank to take place Failure to perfo...

Page 12: ...l line over the frame rail while reinstalling the fuel tank Torque tank hanger bolts to proper specifications Q Reattach filler neck and clamps FASS harness N Carefully reinstall install pick up module making sure the leveling arm is not obstructed by the suction tube Reinstall factory lock ring ...

Page 13: ...tall the 2 10 300 into the T E ports Torque to 40 ft lbs Connect the male end of the wire harness to the female electrical connector on the FASS pump Reconnect the battery Turn key to the On position With the FASS pump on squirt a liberal amount of WD 40 or other lubricant into the T port This procedure will wet the Gerotor and allow for better suction during initial priming Note Do Not Put Thread...

Page 14: ...bolts to 110 inch pounds VERY IMPORTANT REMEMBERING THE POSITION OF THE T PORT THERE IS A SMALL WEEP HOLE IN THE BASE DIRECTLY NEXT TO THE ELECTRIC MOTOR THIS HOLE MUST AIM DIRECTLY TO THE GROUND IMPROPER INSTALLATION OF THE PUMP CAN CAUSE PREMATURE WEAR AND VOID MANU FACTURES WARRANTY ...

Page 15: ...nstall in line fuel filter in an accessible location in the suction line using the HC 1001 s Make sure the fuel flows in the direc tion of the arrow on the canister D Measure and cut fuel line Insert PL 2003 90 Push Lok fitting using oil E Disconnect factory fuel line and injector return line from inlet side of the factory fuel filter and install the DIPF 1003 Torque to 18 ft lbs Do Not use sealan...

Page 16: ... step f H Move the injector return line from step f and stack on top of the outlet line of the factory fuel filter Light bending will be required be very careful not to kink or crack this fuel line Install the Banjo Bolt removed in step f Torque to 18 ft lbs Note Secure all fuel lines with cable ties Cable ties are an economical way to prevent the possibility of problems occurring ...

Page 17: ...lines cover any open ports Bolts and fasteners properly tightened Electrical harness and fuel lines secured and properly tightened Has the system been primed 1 Turn key to the ignition position turning on the FASS pump for 15 sec 2 Crank engine and allow to run for at least 1 minute Check for leaks Start the engine Recheck all fluid and filter connections for leaks This pump comes with a 1 Year Ma...

Page 18: ...nc will repair without cost any product found to be defective during the warranty period parts only or at its option will replace such products in exchange for the product Repair or replacements are warranted for the remainder of the original warranty period All Warranty claims are subject to approval by Diesel Performance Products Inc A Return Material Authorization RMA number must be obtained be...

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