Fass T D10 125G Installation Manual Download Page 6 | Manualshive

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*WE-1001*

46044

Mounting Package Contents

PL-2003

HC-4001

10-300

Ring Terminal

DIPF-1004

BT-14x03

CP-1003

HB-14516

PB-14316

PL-1005

10-302

4 Hex Bolt 3/8” -16x 1 1/2” 3 Hex Bolt 1/4”-20x1 3/4” 4 Locking Nut 3/8” 3 WA-1001D

4 3/8” Washers

RS-2002

RS-2001

PL-1010

PL-1058

BHF-1002

ST-1005Px16”

OR-223

BHN-1001

LW-1001

46260

PL-1004

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Summary of Contents for T D10 125G

Page 1: ...INSTALLATION MANUAL APPLICATION T D10 125G 125GPH 45psi Cummins 5 9L 12Valve with P7100 Injection Pump Standard Pickup Truck 1994 1998 Note Cab and Chassis may require modifications ...

Page 2: ...may require modifications Consult vehicle s manufacturers instructions 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 wa...

Page 3: ...installation recommendations contained herein are guidelines Its important to understand your vehicles accessories and limitations Use good judgment and take in to consideration your vehicles accessories 4 For best results 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 in...

Page 4: ... Step 3 Mount Fuel System Step 4 Install Fuel Line Step 5 Check Installation A fuel pressure gauge is highly recommended to identify fuel filter life and to prevent engine damage H Coolant Heater R Fuel Return to Tank E To Engine Serial Number Location G Fuel Pressure T Fuel Inlet Electric Heater Port 2nd Electric Heater Port ...

Page 5: ...WH 1005 MP 9031 PBR 2001 FL 1002 x15 FL 1056 x3 PFB 2002 Contents FL 1058 x3 ...

Page 6: ... 300 Ring Terminal DIPF 1004 BT 14x03 CP 1003 HB 14516 PB 14316 PL 1005 10 302 4 Hex Bolt 3 8 16x 1 1 2 3 Hex Bolt 1 4 20x1 3 4 4 Locking Nut 3 8 3 WA 1001D 4 3 8 Washers RS 2002 RS 2001 PL 1010 PL 1058 BHF 1002 ST 1005Px16 OR 223 BHN 1001 LW 1001 46260 PL 1004 ...

Page 7: ...rease may be applied to prevent corrosion FUSE RELAY Step 1 Install Electrical Harness 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 46044 and the WE 1001 B Place wire from 46044 and WE 1001 into butt connector Using crimping tool conne...

Page 8: ...tep will be addressed in the Mounting Step 3 Step 1 Install Electrical Harness 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 recom mended NOTE Before installing fittings make sure to inspect for burs or flare imperfections When cutting fuel line make ...

Page 9: ...h the PL 1010 in port S the PL 1004 in the R port using thread tape Torque to 40 ft lbs Push the ST 1005P onto the barb portion of the BHF 1002 Insert O ring into groove B Remove the filler neck and overflow tubes from the truck by loosening the clamps at both ends Step 2 Prepare suction Return lines A Before tank is removed or moved identify ALL areas of clearance be tween the tank and the truck ...

Page 10: ... take measurements so the bottom of the suction tube is only 1 8 no more than 2 quarters stacked from the bottom of the fuel tank Using a razor knife make mul tiple cuts to insure proper length it is easy to shave the suction tube with the razor It is more efficient to cut the tube too long and then correct to proper length than it would be to cut too short I Before drilling marked location clean ...

Page 11: ...NOTE ATTENTION While installing fittings into Titanium pump DO NOT Apply side pressure to draw tube of pump Improper Proper ...

Page 12: ...ill assembly will be used in future steps for correct fitting of brackets Note Bracket maybe flipped to accommodate your application A Using thread tape install the 10 300 into E and the 10 302 into the T port on opposite end Torque to 40 lb ft Note Do Not Put Thread Tape on Flare of Fitting The use of thread sealant is not recommended ...

Page 13: ...erally spray WD 40 or equivalent into water separator nipple lubricating Gerotor E Position the PBR 2001 to the PFB 2002 pump assembly at the mounting location and check for fit Once location is established mark location for mounting in next step D Secure PFB 2002 and RS 2001 with bed bolt in previous step C Unbolt driver side front bed bolt from bed retain bolt for future use Align RS 2001 with P...

Page 14: ...1001D spacers to mount the pump to the bracket Step 3 Mount Fuel System G Assemble the FASS pump bracket PBR 2001 using the RS 2002 spacer between PFB 2002 and PBR 2001 bracket with 4 3 8 bolts nuts and washers Note Torque bolts not flange nut ...

Page 15: ...ilters Attach to system and hand tighten Fuel Filter Install FF 3003 on side of pump with draw tube in the middle of the filter nipple Water Separator Filter Install FS 1001 on water separator nipple without the draw tube Make sure to insert O Ring provided on nipple ...

Page 16: ... to use oil Connect the PL 2003 to the DIPF 1004 Torque to 18 ft lbs F The return line from the injectors must be T d into the return line of the injection pump Assemble the T fitting with 2 HB 14516 and the CP 1003 compression fitting PB 14316 bushing using thread tape Remove the rubber hoses attached to the Injector Pump Return line and Injector Return lines Reuse clamps Install FL 1056 fuel lin...

Page 17: ... The factory suction line can be capped off or removed from the truck The openings on the filter and tank will need to be capped off to keep debris from getting into lines or canis ter To assist with priming your FASS pump crack the FF 3003 Put power to the FASS pump to acti vate the pump When the tone of the pump changes you can tighten up the fuel filter Step 5 Review Installation ...

Page 18: ...nnect the battery 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 Note O Ring must be put back on suction side of pump Failure to do so can result in priming issues cavitation or pressure loses ...

Page 19: ...5 4M Donaldson P551000 10M Donaldson P551311 3M Donaldson P551001 10M Donaldson P551313 3M Fleetguard FS1282 14M Donaldson P553203 3M Fleetguard FS 1000 10M Donaldson P557440 6M Fleetguard FS 1001 10M Fleetguard FF5320 2M Fleetguard FS 1009 14M Fram P8334 2M Fleetguard FS 1212 14M Hastings FF1079 2M LuberFiner LFF8011 Wix 33352 6M LuberFiner LFF8000 Wix 33528 2M Motorcraft FD818 14M Wix 33674 2M W...

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