Horizon Fuel Cell Technologies Automobile Parts 180-1010 User's Manual
Contents
1. 11 1 length Washer Thickness 3 16 Washer Thickness 11 16 Wire Extension oe Quantity Part RS2770 ST 1002 WA 1001A amp WA 1001B WE 1001 eF e Installation Manual FASS FUEL SYSTEM a a a SYSTEM DIAGRAM FUEL TANK FUEL SUPPLY LINE TO PUMP UNIT PUMP FILTRATION UNIT FUEL TO ENGINE MANIFOLD FUEL SUPPLY LINE TO INJECTION PUMP INJECTION PUMP RETURN LINE NOTE LINE WILL T INTO OVER FLOW TUBE NEXT TO FILLER NECK WIRE HARNESS FROM FASS FUEL PUMP TO POWER SOURCE INLET OUTLET PORTS USED FOR PLUMBING ARE MARKED AS FOLLOWED aai i SR E H G the fuel line from the fuel tank enters this port this is the return port back to the fuel tank this is the port leading to the engine s lift pump these are the heater ports for coolant unidirectional The heater DOES NOT HAVE TO BE USED and the read plugs can be left in place this is the gauge port A 0 75psi gauge is recommended if any gauge is being used The 2 12 allen head plugs have no function Installation Manual FASS FUEL SYSTEM Location of the FASS FUEL SYSTEM PUMP FILTRATION UNIT The proper location of the FASS Fuel System on the vehicle is most important e Best performance e Protection from the elements and road debris e Ease of service Suggested location Hint The best place we have found on the Dodge and 1 ton trucks is on the driver s side fra2. FASS Fuel System or installation kit can cause severe engine damage This installation manual applies to the FASS 150 180 1010 45psi contained in the same package The serial number on the installation owners manual package should match the serial number on the outside of the box If it doesn t call the factory This FASS 150 180 1010 45psi 180gph Recommendation FASS 150 180 1010 45psi the Dodge Cummins Truck 1994 1998 with extreme horsepower modifications SAFETY GUIDELINES AND WARNINGS TIP Flush and clean all brass fittings and fuel line free from debris WARNING SECURE VEHICLE FROM ROLLING WARNING Use care not to drill into any electrical wires air lines or other damageable components when drilling WARNING Consult vehicle manufacturer s instructions concerning the electrical system before attempting any electrical connections CAUTION Wear safety glasses when operating power tools such as drills and grinders or when using a punch or chisel CAUTION Properly secure lines to prevent chaffing VERY IMPORTANT THE RETURN FUEL FITTING LOCATED IN THE BASE OF THE FASS FUEL SYSTEM SHOULD NOT BE REMOVED THERE IS A SPECIAL CUT IN THIS FITTING THAT ASSISTS IN REGULATING PRESSURE ALSO DO NOT REMOVE ANY STEEL ALLEN HEAD FITTINGS THESE PORTS WERE USED IN THE MACHINING PROCESS INSTALLATION MANUAL Welcome to the FASS Fuel Air Separation System The installation of the FASS FUEL SYSTEM can be relativ
3. INSTALLATION MANUAL FASS FUEL SYSTEM MODEL NO FASS 150 180 1010 45psi HIGH PERFORMANCE FUEL DELIVERY SYSTEM wam E O FROM Diesel Performance Products Inc SUBJECT Welcome Thank You TO Valued Customer We at Diesel Performance Products Inc DPP would like to thank you for your confidence in purchasing one of the FASS Products Building a quality product and providing excellent customer service is 1 at DPP Behind each fuel system fuel pump are many years of design experience We have implemented very rigorous testing procedures before bringing any item to the market along with very strict manufacturing procedures to provide a superb product Our confidence is evident in the products we make as each product is backed by an industry leading warranty We Diesel Performance Products promote ALL retail business through our dealer network to provide better customer service We are confident that everyone involved is best serviced in this manner We have given our dealer network proper knowledge and support to promote and service our line of products Dealers receive appropriate troubleshooting guides to refer to These have proven to be excellent references for those who choose to use them We provide excellent assistance to our dealers so they in turn can assist their customers DPP has decided to place this information on our website to accommodate all of our customers needs Our R amp D Department in conjunction w
4. Note this step i i f Fj if Photo 3D Photo 3C Assemble the fuel pump bracket to the FASS System using the 5 washers amp bolts The 2 3 16 washers amp x 1 bolts will be used to space the bracket away from the main base of the FASS The 3 11 16 washers amp 1 x 1 bolts will be used to space the bracket away fro the pump assembly of the FASS Refer to photo 2A Torque to proper specifications Assemble 3 8 x 1 2 push lock x mpt fittings into ports label with the letters T and E using tread tape Refer to photo 2A Torque to proper specifications The FB 1001 frame bracket now has multiple slots use the slots at the end of the bracket Assemble the FASS System with bracket to the frame bracket as seen in photo 3B using the 4 3 8 bolts and flanged nuts NOTE This photo is from a different make of truck but the bracket assembly is the same 15 Installation Manual FASS FUEL SYSTEM STEP 3 Mounting FASS System Continued NOTE The L shaped bracket attaches to the cab support on the short beds and 10 to the bed support on the long beds Using photo s 3C and 3D as a guide hold the FASS System as high as possible with both brackets attached into the mounting location While holding to the mounting location mark the mounting points Using a center punch mark the center of each bolt location Drill 2 13 32 holes as seen in photo 3C to mount the
5. e for an unauthorized shop to address the situation problem We will not be responsible Please make sure to fill out your product registration form and return the original form to Diesel Performance Products Inc within 30 days of purchase accompanied with a copy of the urchase receipt Doing so will qualify you for the Limited Lifetime Warranty 19 20 Description Pump Filtration Unit 7 Fuel Pump Bracket aa Owners Manual Electrical Harness 3 8 Fuel Line Y mounting bolts 3 8 mounting bolt and flanged nut Return Manifold 3 8 x 2 Push Lock x M PT 3 8 x Ye Push Lock x Female Flare 3 8 x 3 8 Push Lock x 90 Female Flare Injection Pump Fuel Line Fitting O ring 3 8 Line Hose Clamp 1 Line Hose Clamp Frame Bracket L Shaped Fuse Tap es Flag Terminal Female Ring Terminal Yo x Vo mpt x flared 90 Bulkhead 3 8 x 3 8 Contents Include Quantity 17 2 1 amp 3 1 1 a 6ea Part FASS 150 BR 2001 OM 1001 WH 1002 FL 1001 RM 1003 PL 1001 PL 1002 PL 1003 DIPF 1002 HC 1001 HC 1004 FB 1001 MBFT 187F1AG NRB516 K 28 159 BHF 1001 AARAA 990656009 i pm a QJ M LJ ES o b 21 22 23 24 Contents Include Continued Description Bulkhead O ring as 3 8 mpt Suction Tube
6. ely simple when the following steps are followed 1 Inventory the package components completely Notify place of purchase immediately of any parts missing or damaged 2 We have invested many hours into the development of the installation and_owner s manual s to simplify the installation and operation of the FASS Fuel System Please read the owner s manual and the installation manual completely before attempting installation Understand how the system operates and installation recommendations before beginning installation Most of the questions that you will have will be answered in one of these manuals If you have a question please review the installation or owner s manual 3 The installation recommendations contained herein are suggested installation guidelines only Each installation can and may vary considerably because of the many options and accessories available to the truck market Installation personnel should use good judgment and common sense when installing the FASS Fuel System If any installation procedure is uncertain contact place of purchase Due to training communication and our relationship we have with our authorized dealers we recommend an authorized FASS Fuel Systems dealer for the installation of the FASS System They are prepared to install the FASS System with the most efficiency If a situation problem arises during the installation they are most prepared for that situation problem It may take more tim
7. es wire harness and torque tank hanger bolts to proper specifications Review photo 1F and the location of the return manifold before completing this step Cut the rubber tube to allow the return manifold to junction with the filler tube When assembling the return manifold into the filler tube position it to where the 3 8 junction pipe aims to the outside of the bed It may be necessary to remove approximately 2 3 4 of the rubber where the 3 8 junction tube exits the manifold Assemble the return manifold using the 2 1 3 4 hose clamps Do not tighten at this time 13 Installation Manual FASS FUEL SYSTEM STEP 2 Photo 2A NOTE Preparing Suction Line and Return Line Use the following photo s to complete this step Photo 2B Insert the 3 8 x 1 2 push lock x female flare fitting into the fuel line Remember to oil the fitting and fuel line As seen in photo 2A attach the fitting discussed in the previous step Torque to proper specifications Connect the opposite end of the 17 fuel line addressed in step 2 of this section to the 3 8 junction pipe of the return manifold using a 3 8 hose clamp As seen in photo 2B Now torque all hose clamps to proper specifications YES THE FUEL LINE MAKES A LOOP FROM THE TANK TO THE FILLER TUBE THIS WILL BE ADDRESSED LATER 14 Installation Manual FASS FUEL SYSTEM STEP 3 Mounting FASS System Use the following photo s to complete
8. frame bracket Using the 2 3 8 bolts and flanged nuts mount the frame bracket to the proper Support Torque to proper specifications Torque the 3 8 bolts attaching the frame bracket to the fuel pump bracket to proper Specifications Located on the filters apply motor oil to the o rings Attach fuel filter and water separator Torque to proper specifications 16 Installation Manual FASS FUEL SYSTEM STEP 4 Installing Fuel Line Use the following photo to complete this step Photo 4A Photo 4B Photo 4C Route fuel line from the suction port of the fuel tank to the port of the FASS System labeled with the letter T Cut and attach to the push lock fitting Remember to oil the fitting and fuel line before connecting Route the fuel line from the return manifold to the port on the FASS System labeled with the letter R Cut fuel line and insert the 3 8 x 1 2 push lock x female flare fitting Remember to oil the fitting and fuel line Connect the female flare to the male flared fitting marked with the letter R Torque to proper specifications Disconnect factory fuel line from inlet side of the P7100 Injection Pump and install the DIPF 1002 as seen in photo 4A amp 4B Install the PL 1003 3 8 x 3 8 push lock x 90 female flare fitting into the fuel line Remember to use oil Attach 3 8 x 3 8 push lock x 90 female flare fitting to the injection pump fitting Torque to 18f
9. iew photos 1B 1C amp 1E 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 With the fuel tank empty of fuel now remove it from the vehicle As seen in photo 1A remove the lock ring on the top of the fuel tank Once the lock ring is removed remove pick up module from fuel tank Reviewing photo s 1B and 1C place the lock ring back into place for measurement reasons Lay the grommet into proper location and use a punch to mark the center Drill a 1 1 hole catch all debris example cup Using photo 1D assembly the pick up assembly Use pipe tape on the pipe threads Insert the grommet into the 1 hole Place the pick up assembly into grommet 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 Before cutting the suction tube triple check the measurements it is much more efficient to cut the tube to long and then correct to proper length than it would be to cut to short With proper length being obtained with the suction tube kit debur and flush assembly Place the assembly into the grommet as seen in photo 1E Reinstall install pick up module 12 Installation Manual FASS FUEL SYSTEM STEP 1 Removing amp Preparing Fuel Tank Continued 15 16 17 18 Cap factory suction line Reinstall fuel tank Remember to connect both factory fuel lin
10. ith our Dealer Support Department is continually searching for ways to improve quality expand our product line and provide superb support to our network of dealers so they can support their customers Please make sure to fill out your product registration form and return the original form to Diesel Performance Products Inc within 30 days of purchase accompanied with a copy of the urchase receipt Doing so will qualify you for the Limited Lifetime Warranty Steps to customer satisfaction can be found on the next page STEPS TO CUSTOMER SATISFACTION We want you to be happy with your FASS Fuel System Customer satisfaction your satisfaction is the all important ingredient for success in our business as it 1s in any other Normally warranty problems can be resolved by your Dealer s sales or service departments That s why you should always talk to your Dealer s Service department first If you re not satisfied with the dealership s response at this level Diesel Performance Products Inc DPP recommends that you follow these steps in order STEP 1 Discuss the problem with the owner or General Manager of the dealership STEP 2 If your dealership in unable to resolve the problem contact Diesel Performance Products Inc Customer Care Center in writing the address is located on page 14 of this manual or fax it to 636 433 5913 Be prepared to provide the Customer Center with the following information Your Name addres
11. me rail up underneath the bed of the truck and in front of the rear tire ae ne fo r oie FUEL TANK JU FASS FUEL SYSTEM NOTE Throughout this manual there are photos of the FASS 150 with the previous mounting bracket part BR 1001 The instructions for mounting the new bracket are the same throughout this manual except for the mounting of this bracket to the FASS for which there are pictures 10 Installation Manual FASS FUEL SYSTEM BEGIN INSTALLATION STEP 1 Removing amp Preparing Fuel Tank Use the following photo s to complete this step Some of the photo s are of a different application procedures are the same Photo 1B Photo 1D Photo 1E Photo 1F Very Important Before removing the fuel tank identify ALL areas of clearance between the tank and bed to install the draw tube assembly 1 Remove the filler neck tube from the truck by loosening the clamps at both ends 1 Installation Manual FASS FUEL SYSTEM STEP 1 Removing amp Preparing Fuel Tank Continued 10 11 12 13 14 Disconnect overflow tube from the fuel tank Disconnect the factory suction and return line The factory lines are removed by pressing in on the two tabs located in the connecting harness These tabs are opposite of each other Disconnect the factory electrical harness located between the suction and return lines on top of the fuel tank Before completing the next step rev
12. s and daytime phone number Model and Serial Number Not Model Number Dealer contact name and phone number Date of purchase Nature of Problem Once you have followed the two steps described a DPP representative will review your situation DPP will then follow up by contacting the dealer for more information Depending on the situation a representative from the selling dealer or a representative of DPP may elect to contact you Thank you for your business from the men and women of Diesel Performance Products Inc FILTER CROSS REFERENCE SHEET Cross Reference List for the FASS 150 Series Fuel Filter Recommended Fuel Stratapore or Microglass Filter Media BRAND Part Micron Rating Material FASS FF 1010 10 Stratapore FASS FF 1003 3 Stratapore CIM TEK 70032 10 Microglass CIM TEK 70213 3 Microglass Fleetguard HF6601 8 Cellulose Synthetic Fleetguard HF6610 16 Cellulose Fleetguard HF6613 12 Microglass Fleetguard HF6607 6 Microglass Fleetguard HF 6604 3 Microglass Caterpillar 318642 Cross Reference List for the FASS 150 Series Water Separator Recommended Water Stainless Steel Water Separator Filter Media BRAND Part Micron Rating Material FASS WS 1001 144 Stainless Steel Water Separator Fleetguard FS1023 144 Stainless Steel Water Separator NOTE The use of a hydraulic fuel filter is because the canister 1s much thicker and provides more durability than a fuel filter canister WARNING Installing the improper
13. t lbs As seen in photo 4C Connect the remaining fuel line to the push lock fitting located in the port labeled E on the FASS System Remember to use oil The return line from the injectors must be T into the return line of the P7100 injection pump 17 Installation Manual FASS FUEL SYSTEM STEP 5 Installing Electrical Harness Use the following photo to complete this step 1 Connect the male end of the wire harness to the female electrical connector on the FASS System 2 Route the wire harness along the frame rail and into the engine compartment and connect the wire extension part WE 1001 to the female end of the WH 1002 cab 3 Rout the red wire of the wire extension through rubber grommet located in the fire wall 4 Using the fuse tap amp flag terminal connect the Red lead from the wire extension to a terminal on the circuit breaker board that is hot when the key is on Note Connect the fuse tap to the hot side of the fuse O Using the ring terminals connect the green wire of the WH 1002 wire harness to the negative post and the red wire to the positive post of the battery 6 Secure the relay in an upright position 7 Properly secure the wire harness and fuel lines with wire ties 18 Installation Manual FASS FUEL SYSTEM STEP 6 FINAL CHECK 1 Bolts and fasteners properly tightened 2 Electrical Harness and Fuel Lines secured or properly tightened 3 Prime the fuel sys
14. tem Refer to owner s manual 4 Check for leaks 5 Start the engine 6 Recheck all fluid connections and filters for leaks NOTE The electric fuel pump runs continuously while the engine is running The fuel pump on the FASS System will feel warm or hot to the touch Please make sure to fill out your product registration form and return the original form to Diesel Performance Products Inc within 30 days of purchase accompanied with a copy of the urchase receipt Doing so will qualify you for the Limited Lifetime Warranty Revised 4 22 08 19
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