Fuel Pro 482 Technical Manual

2016 ©DAVCO Technology, LLC.

FOR UPDATED INFORMATION, VISIT WWW.DAVCO.COM

F1212 REV E

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TABLE OF CONTENTS

Applications, Models, and Options. . . . . . . . . . . . . . . . . . 1

How it Works. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

“SEEING IS BELIEVING”® . . . . . . . . . . . . . . . . . . . . . . . . 2

Dimensions and Specifications. . . . . . . . . . . . . . . . . . . . . 3

• Important Safety Precautions. . . . . . . . . . . . . . . . . . . . 4

Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Wiring the 12VDC Pre-Heater to the SAM Chassis . . . . . 8

Wiring Instruction the 12VDC Pre-Heater to the DDEC . 11

120VAC Heater Installation (with block Heater) . . . . . . . 15

Fuel Port Threads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 18

Filter Change Procedure . . . . . . . . . . . . . . . . . . . . . . . . . 19

Service Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Visual Diagnostics – Air vs. Vapor Bubbles . . . . . . . . . . 21

Diagnostic Procedures - Air Leaks . . . . . . . . . . . . . . . . . 22

Diagnostic Procedures - Heater Testing . . . . . . . . . . . . . 23

Service Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Service Parts — Pre-heaters. . . . . . . . . . . . . . . . . . . . . . 25

Warranty Policy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Parts Return Policy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27


FUEL PRO® 482TECHNICAL MANUAL

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F1212 REV Ewww.davco.com800-328-2611 Saline, MI 48176P. O. Box 487DAVCO Technology, LLC

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APPLICATIONS, MODELS, AND OPTIONS

HOW IT WORKS

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Applications:

• Detroit Diesel DD13, DD15 and DD16 Engines

• Freightliner

• Western Star

Models and Options

• 12VDC pre-heater

• 120VAC pre-heater

• Water-in-fuel sensor (WIF)

• 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.

ENGINE FUEL MODULE

FUEL TANK

FUEL PRO

The Fuel Pro 482 is customized specifically for the Detroit Diesel DD13, DD15 and DD16 Engines.


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• See when NOT to change the fuel filter.

• See the condition of the fuel. Seeing what collects on the filter media or what’s happening inside the clear cover can help diagnose many fuel and mechanical conditions.

• “Filter on Top” configuration. Water and debris removed from the fuel falls to the lower chamber and stays away from the filter media resulting in longer filter life.

• Built in protection when priming the fuel filter. Unfiltered fuel is kept on the “dirty” side of the filter media during priming ensuring only clean fuel reaches the engine.

• Patented media. The “Best in Class” StrataPore™ media removes 98% of free and emulsified 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 filter, the fuel rises to a non-contaminated section of the filter, providing optimal filtration while maintaining lowest restriction.

Fuel level at filter wrap level. Even though the fuel level is now more than half of the filter element, the fuel is still flowing through clean media at minimal restric-tion levels. The filter still has significant life remaining.

The filter element is now completely covered by fuel. At this point, all of the media’s surface area is utilized. Restriction is increasing and the filter element should be changed at the next scheduled maintenance interval.


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Specifications

Height Overall 14 in (355.6 mm)

Depth Overall 6.58 in (167.1 mm)

Width, Max. 8.35 in (212.1 mm)

Mount Bracket Centers 3.940 in (100.1 mm)

Weight, Dry 10-12 lbs

Fuel In Connection 1/2 in-14 NPTF

Fuel Out Connection 1/2 in-14 NPTF

Filter Service Clearance Min

3.5 in (88.9 mm)

Max. Fuel Flow 180 gph

Electric Pre-heater 12VDC, 250 W, 18 A

Overnight heater

Filtration Performance

Fuel Pro 482 at 100 GPH (EST.)

MicronCoarse Water Removal (%)

Emulsified Water Removal (%)

Dirt Holding Capacity (grams)

7 mic 100 98.7 157

0.0

0.5

1.0

1.5

2.0

2.5

0 25 75 125 175 22550 100 150 200

7 micron

Diff

eren

tial P

ress

ure

(in-H

g)

Flow (gph)

RESTRICTION VS. FLOW

5.41137.4

4.74120.4

3.940100.1

8.35 MAX212.1

2.3259

3.7094

FUEL OUT

3.5088.9

RECOMMENDEDMIN. SERVICE HEIGHT

.7017.8

2.5063.5

1.1228.4

.531

2 HOLES13.5

14.00355.6MAX.

11.85301

MAX.

42.11.66

.4611.8

15.00381

MIN.

FUEL IN1/2"-14 NPTF

FUEL OUT1/2"-14 NPTF

1.1228.4

.7418.8

1.2130.7

.7519

2.5063.5

FRONT VIEW RIGHTLEFT TOP VIEW

DIMENSIONS AND SPECIFICATIONS


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• IMPORTANT SAFETY PRECAUTIONS

General Safety Precautions• Read all instructions before use to avoid injury.

• To avoid serious injury or death, follow the safety information in this document.

• Keep this manual. If you need to replace the manual, call customer service at 800-328-2611 or visit www.davco.com/documents for a replacement.

• Read all product safety labels.

• Refer to appropriate regulations for environmental and workplace safety rules.

WARNING: To prevent personal injury• Scalding hazard: When diesel fuel is circulated through an operating engine, it can become very hot. Do not al-

low fuel to come in contact with eyes or unprotected skin. Allow the engine and fuel to cool to ambient tempera-ture before replacing the 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 source. To elimi-nate the potential for fire, keep open flames, sparks or other potential ignition sources away from the work area. Do not smoke during filter replacement or service operations.

• Inhalation Precaution: Always perform engine or vehicle fuel system maintenance in a well ventilated area that is kept free of bystanders.

• The ignition key must be in the off position, unless otherwise directed. To avoid unintentional engine startup, use a lockout key and/or signage to alert personnel that work is being performed.

Government Regulations• Engine fluids (oil, fuel, and coolant) may be a hazard to human health and the environment. Handle all fluids and

other contaminated materials (such as filters and rags) in accordance with applicable regulations. Recycle or dis-pose of engine fluids, filters, and other contaminated materials according to applicable regulations.


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INSTALLATION INSTRUCTIONS

Step 1Install the fuel INLET and OUTLET fittings into the Fuel Pro 482 facing upward at a 45° angle towards the back of the unit.

Step 2Locate the two holes on the driver side bumper support bracket just forward of the steering box. Note: There will not be a steering box in models that include rack and pinion steering.

Step 3Attach the Fuel Pro 482 to the front hole using a ½" bolt, washer and lock nut (for hand clearance). Rotate the unit inward and attach the Fuel Pro 482 to the rear hole using a ½" bolt, washer and lock nut. Torque both bolts to 96 ft-lb.

Step 4Disconnect the fuel supply line at the filter module and remove the zip ties.

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INSTALLATION INSTRUCTIONS (CONTINUED)

Step 5Rotate the fuel module inlet fitting towards the front of the truck and tighten.

Step 6Install and route a new piece of 5/8" fuel tube toward the front of the truck coming from the fuel module inlet fitting.

Step 7Route the new 5/8" fuel line coming from the inlet on the engine fuel module to the outlet of the Fuel Pro 482, cut and connect.

Step 8Install a 5/8" union on the fuel supply line and attach a new piece of fuel tubing to the compression fitting (ap-proximately 6’ long). Cover the fuel line with 1" diameter split loom. Install zip ties and secure using a plastic clamp.


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INSTALLATION INSTRUCTIONS (CONTINUED)

Step 9Connect the fuel supply line to the inlet on the Fuel Pro 482.

Step 10Remove the vent cap from the Fuel Pro 482. Prime the unit by pouring fresh diesel fuel into the clear cover to fill to the top of the filter.

Step 11Use the hand primer pump on the fuel module to purge the remaining air from the fuel lines.

Step 121. Install the vent cap. Tighen the vent cap by hand

until it clicks

2. Start the engine and run for one minute. While the engine is running, slowly open the vent cap and al-low the fuel to drop to approximately one inch above the collar.

3. Tighen the vent cap by hand until it clicks. It is nor-mal for the fuel level to vary after the initial start-up and during engine operation. Filter performance is not affected.

4. Check the fuel system for any leaks.

5. Installation is complete.


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Step 1Locate the 12VDC preheater and connect it to the chas-sis harness.

Step 2Route the chassis harness around the power steering reservoir toward the firewall.

Step 3Connect the ground eyelet from the chassis harness to the ground stud on frame rail just to the right of the shock and zip tie as needed.

Step 4Route the 12 volt power lead towards the SAM Chassis Connector. (Zip tie harness as needed)

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WIRING THE 12VDC PRE-HEATER TO THE SAM CHASSIS

If installing a 12VDC heaters, coat the thread with a light coat of pipe sealant and torque to 15 to 30 Ft Lbs.

FUEL PRO® 482TECHNICAL MANUALT e c h n o l o g y , L L C

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Step 5Locate connector X57 and release the yellow handle to remove the connector.

Step 6Remove the cover for the connector X57 by lifting up-wards on the tabs.

Step 7Locate cavity 15 on X57 and remove the cavity plug.

Step 8Insert the 12VDC preheater power wire into cavity 15 of the X57 connector.


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Step 9Reinstall the cover for X57 connector, push until tabs lock.

Step 10Reinstall the X57 to SAM Chassis Connector and lift handle to secure.

Step 11Install the 20amp/35amp circuit breaker relay in the R1 location

Step 12Install the 20amp fuse in the F2 location

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Step 13Mark the inside of cover showing the added circuits R1 and F2 with a red or yellow marker and reinstall cover. .

Step 1Locate DDEC box under the hood.

Step 2Remove the cover from DDEC6 PDB by squeezing the two tabs.

WIRING INSTRUCTION THE 12VDC PRE-HEATER TO THE DDEC


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Step 3Remove the PCB by pushing in the two tabs as shown

Step 4Remove the rear cover of DDEC6 PDB using a straight pick as shown.

Step 5Remove the fuses from DDEC6 PCB (note locations for replacement)

Step 6Remove the red plastic terminal retainer as shown.


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Step 7Zip tie the 12V power lead to the DDEC6 PDB harness and cut to length.

Step 8Cut off the SAM chassis terminal and seal.

Step 9Strip the power wire on the power lead and crimp the electrical terminal as shown.(P/N:23-13215-301)

Step 10Insert the electrical terminal into the socket shown (fuse location F5).


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Step 11Reinstall the rear cover as shown below.

Step 12Replace the red plastic terminal retainer as shown.

Step 13Replace fuses as they were before install and install a 20 amp fuse in F5 location.

Step 14Replace the DDEC6 PDB on mount, replace cover and mark the location of 20amp fuse for pre-heater


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Step 1The 120VDC block heater is located to the left of the fuel filter module.

Step 2Locate the 120VAC receptacle where the heater plug snaps into place. This receptacle is located either below the driver’s door or to the right of driver’s door.

Step 3 Remove the plug from the receptacle and remove the cord from the engine block.

Step 4 Connect the straight end of the “Y” cord (DTNA P/N 06-68843-002 ) into the engine block.

Step 5 Connect the 90° end of the “Y” cord to the 120VDC heater on the Fuel Pro 482.

Step 6 Route the “Y” cord towards the receptacle, zip tie where needed to secure.

Step 7 Push the male end of the plug into the receptacle until the plug snaps into place.

Step 8 Installation complete.

120VAC HEATER INSTALLATION (WITH BLOCK HEATER)

Block Heater Fuel Filter Module


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Step 1The 120VAC block heater is located to the left of the fuel filter module. (See Figure 1)

Step 2Locate the 120VAC receptacle where the heater plug snaps into place. This receptacle is located either below the driver’s door or to the right of driver’s door.

Block Heater Fuel Filter Module Receptacle

Step 3 Remove the plug from the receptacle and remove the cord from the engine block.

Step 4 Connect the straight end of the “W” cord into the engine block.

Step 5 Connect the longest end of the “W” cord that has the 90° end into the oil pan heater.

Step 6 Route the “W” cord towards the receptacle, zip tie where needed to secure. Installation is complete.

Step 7 Push the male end of the plug into the receptacle until the plug snaps into place.

120VAC HEATER INSTALLATION (WITH BLOCK HEATER AND OIL PAN HEATER)


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FUEL PORT THREADS

Fuel Pro 482 OEM fuel ports are metric thread vs Aftermarket pipe thread

• Factory Installed Fuel Pro 482s have M22x1.5 metric thread fuel ports. (Figure 1)

• Aftermarket retrofit kit fuel ports have pipe threads with a ¾" x ½" bushing. (Figure 2)

M22 X 1.5 Metric threads

Figure 2

¾ in. NPT to ½ in. NPT bushing

Figure 1


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PREVENTIVE MAINTENANCE

• Weekly – Drain water

• Turn off the engine and open the vent cap.

• Place a suitable eight ounce, plastic or metal container under the drain valve at the base of the Fuel Pro and open the valve.

• 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.

• Tighten the vent cap by hand until it clicks.

• Start the engine. Raise the RPM for one minute to purge the air from the system.

• Every filter change

• Change the cover and vent cap o-rings (included with the service filter kit).

• Every 12 months

• Check all electrical connections for corrosion. Check all fuel fittings for leaks.

• Extreme winter or salt corrosion environments may require lubrication of the collar threads with anti-seize lubricant every 180 days.


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FILTER CHANGE PROCEDURE

1. Remove the vent cap and open the drain valve to drain the fuel below the collar level.

2. Remove the collar (using a DAVCO wrench) then remove the clear cover.

3. Remove the filter, cover and vent cap seals. Dispose of properly.

4. Using a clean shop rag, clean the cover, the collar and threads on the Fuel Pro body.

5. Install a new filter, cover seal and vent cap seal.

6. To tighten the collar with the wrench, simultaneously ap-ply downward pressure to the top of the clear cover until it is seated on the body of the Fuel Pro and hand tighten

the collar until it no longer spins freely. Torque the cover assembly by rotating the collar clockwise two additional ribs using the collar wrench (~18 ft-lbs).

7. Prime 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. Slowly open the vent cap and allow the fuel to drop to about one inch above the collar.

9. Close the vent cap. Tighten the vent cap by hand until it clicks. It is normal for the fuel level to vary after the initial start-up and during engine operation. Filter performance is not affected.

Collar Wrench

P/N DVC482017

8 in.

Tightening the collar with the wrench

Simultaneously apply downward pressure to the top of the clear cover until it is seated on the body of the Fuel Proand hand tighten the collar until it no longer spins freely. Torque the cover assembly by rotating the collar clockwise two ad-ditional ribs using the collar wrench (~18 ft-lbs).

Note: The DAVCO Fuel Pro collar is designed to be removed with a DAVCO wrench. Collars damaged as a result of not using the DAVCO wrench will not be covered under war-ranty.

Recommended FilterBrand P/N Micron

Detroit Diesel A000090 3651 7

Fleetguard FS19915 7


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SERVICE PROCEDURES

Bypass valve assembly 1. Remove the vent cap and open the drain valve, drain

the Fuel Pro 482 completely.

2. Remove the collar (using a DAVCO wrench) then remove the clear cover.

3. Remove the filter, cover and vent cap seals. Dispose of properly.

4. Using a clean shop rag, clean the cover, the collar and the threads on the Fuel Pro 482 body.

5. Flush the inside of the Fuel Pro 482 body with clean diesel fuel to clear it of any debris.

6. Remove the bypass valve assembly and discard.

7. Remove the protective cap from the replacement by-pass valve assembly.

8. Install the replacement bypass valve assembly into the Fuel Pro 482 body (torque to 20 ft-lbs).

9. Install a new filter, cover seal and vent cap seal.

10. Simultaneously apply downward pressure to the top of the clear cover until it is seated on the body of the Fuel Pro/Diesel Pro and hand tighten the collar until it no lon-ger spins freely. Torque the cover assembly by rotating the collar clockwise two additional ribs using the collar wrench (~18 ft-lbs).

11. Prime the unit by filling the clear cover with clean diesel fuel until it reaches the top of the filter.

12. Install the vent cap. Tighten it by hand until it clicks.

13. Start the engine and run for one minute. Slowly open the vent cap and allow the fuel level to drop to about one inch above the collar.

14. Close the vent cap. Hand tighten it until it clicks.

Bypass Valve

Check Valve

Check-valve assembly 1. Remove the vent cap and open the drain valve, drain

the Fuel Pro 482 completely.

2. Use a back-up wrench to hold the check-valve body and remove the fuel hose from the inlet of the Fuel Pro 482.

3. Remove the check-valve assembly.

4. Remove the spring retainer, spring and ball.

5. Clean and inspect the check-valve body. Replace if damaged or if the ball seat is not smooth.

6. Install the new ball, spring and spring retainer. Note: The spring retainer snaps into a groove in the check-valve body.

7. Apply liquid thread sealant to check-valve body threads.

8. Replace the check-valve assembly into the Fuel Pro 482 body (torque to 45 ft-lbs).

9. Connect the fuel inlet hose.

10. Prime the Fuel Pro 482 by filling the clear cover with clean diesel fuel until it reaches the top of the filter.

11. Install the vent cap. Hand tighten it until it clicks.

12. Start the engine and run for one minute. Slowly open the vent cap and allow the fuel level to drop to about one inch above the collar.

13. Close the vent cap. Tighen by hand until it clicks.


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VISUAL DIAGNOSTICS – AIR VS. VAPOR BUBBLES

AIR BUBBLES VAPOR BUBBLES

Air Bubbles

Air bubbles are caused by any air leak on the vacuum (suc-tion) side of the fuel system from the fuel tank pick-up to, and including, the lift pump.

If there is an air leak in the fuel system, air bubbles will be present in the clear cover of the Fuel Pro follow Diagnostic Procedures (page 22) for air leak diagnostics. If there are no bubbles present in the Fuel Pro cover and the engine continues to run rough, lopes or has a loss of power, there may be an air leak between the Fuel Pro outlet port and lift pump inlet. This type of air bubble can be seen if a sight tube is installed at the lift pump inlet. Air bubbles may also be visible in the fuel return (spill) hose out of the fuel gallery. These leaks are easily eliminated by checking and torquing the fuel fittings in the area of the leak.

NOTE 1: A quick procedure to determine if the air leak is between the fuel tank and the Fuel Pro is to remove the Fuel Pro inlet hose and route a new hose from the Fuel Pro inlet into a container of fuel or the fuel tank fill cap opening. Start 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 inside the Fuel Prois lower than the atmospheric pressure in the fuel tank. Vapor bubbles can vary from champagne size up to ¼" in diam-eter. They may increase in size or volume as engine rpm increases. The lower pressure draws the entrained air/vapor out of the fuel and these bubbles will be visible as the fuel exits the Fuel Pro.

As the fuel enters the lift pump, it is pressurized and the bubbles are compressed back into the fuel. There will be no bubbles on the fuel return side of the system. These vapor bubbles will not affect the performance of the engine.

NOTE 2: An easy way to determine the difference between vapor and air bubbles is by temporarily removing the filter element from the Fuel Pro. Fill the cover with clean diesel fuel, replace the vent cap. Tighten the vent cap by hand until it clicks. Re-run the outlet fitting sight glass test. If there are no bubbles present in the sight glass then they were vapor. If bubbles are still present then they are air. If air bubbles still exist, re-run the test in NOTE 1 to eliminate the chassis plumbing as a variable.

There is no troubleshooting or repair procedure re-quired for vapor bubbles. Vapor bubbles do not cause performance issues and will not be present after the lift pump.

There are two kinds of bubbles that may be visible at the fuel pump inlet of a diesel fuel system. The bubbles can be characterized as either air bubbles or vapor bubbles.


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Every Fuel Pro 482 is factory tested for leaks and is marked with a traceable number to show that it has passed produc-tion testing.

Most field issues associated with leaks are related to loose fittings. These leaks are easily eliminated by checking and torquing the fuel fittings in the area of the leak. Some fittings may also require the application of liquid Teflon sealer.

NOTE: All suction side fuel filters experience bubbles. It is normal to see champagne size bubbles in the Fuel Pro 482 at the Fuel Pro outlet or at the lift pump.

IN ORDER TO RETURN A FUEL PRO 482 FOR EVALU-ATION, THE FOLLOWING PROCEDURES/TESTS NEED TO BE COMPLETED BEFORE REQUESTING A DAVCO RGA (RETURN GOODS AUTHORIZATION).

I. Air Leak: Air bubbles will be visible in the clear cover of the Fuel Pro 482 if the leak originates from the fuel tank up to the fuel filter. The following is a quick test to isolate the air leak source.

• Bubbles Visible: Remove the Fuel Pro 482 inlet hose.

i. Install a jumper hose from the Fuel Pro 482 to the fuel tank (through the fill cap) or to a container of fuel.

ii. Start the engine. If this eliminates the air bubbles, the air source is at the fuel tank fit-tings or hose connections.

1. Tighten all fittings and connectors

2. Retest

iii. If air bubbles persist, the air source is on the Fuel Pro 482 side of the system:

1. Tighten all fittings on the Fuel Pro 482.

2. Simultaneously apply pressure to the top of the clear cover until it is seated on the body of the Fuel Pro and tighten the collar until it no longer spins freely. When completed, tighten two addi-tional ribs on the collar using the collar wrench.

3. If the drain valve is suspected, install a plug in place of the drain valve (for test purposes only).

iv. If air bubbles continue to persist, test as follows:

1. Remove the Fuel Pro 482 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 482 is equipped with a preheater, do not remove the preheater.

3. Apply 15 PSI of air pressure at the fuel inlet. Immerse the Fuel Pro 482 in a tank of water and look for air bubbles.

4. Correct the source of the air leak and retest.

• Bubbles Not Visible: If there are symptoms of sucking air (indicated by engine loping/rough run-ning performance/power loss, etc.) and there are no bubbles in the clear cover, the air leak is either at the Fuel Pro 482 outlet fitting, vent cap o-ring, the lift pump inlet connection, or the fuel hose/connections to the lift pump. Inspect and tighten fittings as needed.

II. Excessive Restriction: If the fuel level is at the top of the filter, replace the fuel filter. The Fuel Pro 482 will not cause excess system restriction if the fuel level is below the top of the filter. The only exception is if the grommet is not installed in the bottom of the filter element.

III. Loss of Prime: When air is introduced into the fuel system, (i.e. draining water from the Fuel Pro 482 or when replacing the fuel filter) a check valve is needed to keep the fuel system primed from the Fuel Pro 482 back to the fuel tank. A check valve is standard with all Fuel Pro 482s.

• To test for proper check valve operation, remove the fuel inlet hose and open the vent cap. Fuel should not flow out of the Fuel Pro 482, although a slight seepage of fuel is normal.

• If fuel drains back to the fuel tank, remove the check valve assembly at the fuel inlet fitting. Disassemble the check valve assembly. Clean and inspect. Replace the assembly if any cuts, grooves or nicks are evident in the ball or body seat. Reinstall the check valve assembly.

DIAGNOSTIC PROCEDURES - AIR LEAKS


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DIAGNOSTIC PROCEDURES - HEATER TESTING

There are various configurations of electric pre-heaters and thermoswitches available for the Fuel Pro. These include 12VDC pre-heaters, 24VDC pre-heaters, 120VAC pre-heat-ers/thermoswitches, and combination pre-heater thermo-switches. The voltage and wattage ratings are stamped either on the sheath or the hex of each component for identification.

Equipment Needed• A precision low resistance ohm meter capable of mea-

suring 1/10th ohm or less.

• Current flow meter (clamp-on type for DC current).

• Ice, dry-ice, CO2 or some means of chilling the thermo-switch.

• A flameless source of heat. (ie: infrared heat lamp, etc.) Note: A Vortex tube is a good tool to heat and cool for testing.

• DO NOT USE a test light that has a wire probe for any of these tests. If the wiring insulation is punctured, moisture and road salt can penetrate into the wires creating a corrosion issue and potential failure.

Draining the Fuel Pro1. Shut off the engine and set the parking brake.

2. Attach a length of hose to the drain valve and place a receptacle under the Fuel Pro.

3. Loosen the vent cap on top of the clear housing. Open the drain valve and drain the fuel into the receptacle.

4. When the fuel is drained, close the drain valve.

Pre-heater Operation Test1. Disconnect the pre-heater from the 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 is in the acceptable range.

Pre-heater Watts Resistance Range (ohms)

12VDC (two pin) 250 W 0.6 to 0.8 @ 77°F (25°C)

12VDC (single pin) 250 W 0.6 to 0.8 @ 77°F (25°C)


12VDC (two pin) 150 W 0.8 to 1.1 @ 77°F (25°C)

24VDC (two pin) 250 W 2 to 2.5 @ 77°F (25°C)



24VDC (two pin) 150 W 3.6 to 4.1 @ 77°F (25°C)

120VAC 75 W 173 to 203 @ 77°F (25°C)

120VAC 37 W 369 to 411 @ 77°F (25°C)

Combination Pre-heater Thermoswitch Perfor-mance Test1. Disconnect the harness from the heater/thermoswitch

combination unit.

2. Using one of the cooling methods listed under "Equip-ment Needed", reduce the temperature of the thermo-switch to below 40° F.

3. Connect the ohm meter leads to the pre-heater pins. Use Table 1 to determine whether the pre-heater resis-tance value is in the acceptable range.

4. Using one of the pre-heating devices listed under “Equipment Needed”, raise the temperature of the com-bination pre-heater to 70°F. The ohm meter should read “open circuit” for the combination units.

12 VDC PTC/24VDC Performance Test1. Disconnect the harness from the heater.

2. Connect the ohm meter leads to the pins of the heater. Use the following to determine whether the pre-heater resistance value is in the acceptable range.

PTC Heater Watts Resistance Range (ohms)

12VDC (PTC) 195 W 0.4 to 0.6 @ 77°F (25°C)

24VDC (PTC) 195 W 2.0-3.0 @ 77°F (25°C)

12VDC (PTC) 155W 0.95 to 1.2 @ 77°F (25°C)


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SERVICE PARTS

Service Kits

Name Included in Kit Daimler P/N

Check valve service kit

Ball, spring and retainer

DVC101132

Check Valve Assembly

Check valve service kit and body

DVC482012

ESOC service kit (not shown)

Fitting and dust cover

DVC102844

O-ring service kit Vent cap* and Cover O-rings

DVC482022

Vent cap service kit

Vent cap* and Vent cap O-ring

DVC240023DAV

*Note: The torque-limiting vent cap replaces the toothed vent cap (which was removed with the DAVCO wrench). The vent cap provided as a service part may be a different type than the one on the original unit.

Service Parts

Name Daimler P/N

Bypass Valve DVC482010SVC

Check Valve Body DVC482011

Collar DVC482003

Collar Wrench DVC482017

Cover and Collar DVC482044

Drain Valve DVC102008

Pre-heater - 12VDC DVC103528

Pre-heater - 120VAC DVC103242

Spring DVC380056

PARTS ARE AVAILABLE THROUGH DAIMLER TRUCKS NORTH AMERICA

Metal Collar Wrench, Part Number DVC482017


Drain valve

Collar

Cover, Collar

Spring

Check valve body

O-ring service kit

Vent cap* service kit

Check valve service kit

By-pass valve

Filter Element

12VDC Pre-heater

120VAC Overnight Heater

Check Valve Service Kit (P/N DVC101132

Check Valve Body (P/N DVC482011)

Check Valve Service Assembly (P/N DVC 482012)


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PRE-HEATER PART NUMBERSDescription Part Number

120VAC Pre-heater

75W, 120V, 174-203Ω

103242

12VDC Pre-heater (Metri-Pack)

250W, 12V, 0.67-0.78Ω

103528

12VDC Pre-heater (Weather-Pack)

250W, 12V, 0.67-0.78Ω

103529

SERVICE PARTS — PRE-HEATERS


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Product WarrantyDiesel Pro® 243, Diesel Pro® 245, Fuel Pro® 382, Fuel Pro® 482, Fuel Pro® 483, Fuel Pro® 485, Fuel Pro® 486, Fuel Pro® 487, Industrial Pro®, Shop Pro®, Pro-Chek®, Sea Pro® Please review DAVCO’s Product Warranty terms and conditions carefully before installing and/or using a DAVCO product. By installing and/or using the product, you agree to be bound by the following:

DAVCO Technology, LLC warrants these products to be free of defects in material and workmanship for five-years, 500,000 miles or 10,000 hours (whichever comes first) and electrical parts for two-years, 200,000 miles or 4,000 hours (whichever comes first) from the purchase date*. The Shop Pro motor has a one-year warranty from the purchase date.

REN Products, EyeMax®, Electronic Gauges, Electronic Dipsticks and Fuel Pro® 384 DAVCO Technology, LLC warrants these products to be free of defects in material and workmanship for two-years or 200,000 miles (whichever comes first) from the purchase date.

This Warranty does not apply to:• Failure or inadequate performance due to improper installation, misuse, misapplication, faulty installation, alteration/

modification, poor maintenance, neglect, accident, or conditions resulting from actions outside DAVCO’s control, in-cluding but not limited to contaminated and unapproved fluids.

• Downtime, loss of use, 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 installed with aftermarket parts or altered or modified in any way.

• Normal wear and tear, abuse, vandalism, acts of God, improper storage or handling, disasters such as flood, fire, or war, failure to operate, maintain or repair in accordance with instructions, or failure to repair the vehicle into which the prod-uct is installed in accordance with the vehicle manufacturer’s instructions or common maintenance practices.

This warranty is the sole warranty made by DAVCO. DAVCO makes no other warranties, expressed or implied, of merchant-ability or fitness for a particular purpose.

In the unlikely event of a defective product, DAVCO will either rework the defective product or replace it at DAVCO’s discre-tion. If you feel you have a warrantable issue, contact DAVCO at 800-328-2611 for a Return Goods Authorization (RGA) number **. An RGA number is required prior to the return of any product.

* Purchase Date: The date of the first retail purchase of a new vehicle or piece of equipment from the OEM dealer or factory. For “Over the Counter” purchase: The date of sale to the first retail customer.

**Products submitted for Warranty consideration will be inspected by DAVCO personnel. Re-work or replacement will be based on DAVCO’s Warranty procedure and/or the results of their evaluation. DAVCO’s Warranty Program does not in any way constitute a product guarantee.

WARRANTY POLICY


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Parts Return General PolicyNote: A Return Goods Authorization (RGA) must be obtained from DAVCO prior to returning any products. Returns may be accepted under the following circumstances:

Order Shipping Error: A credit against the original invoice, including freight charges for both ways will be 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. Additional restock fees may apply. Product(s) will be inspected for “like new” condition and additional costs will be the responsibility of the customer. No obsolete parts may be returned.

Freight charges for return(s) will be the responsibility of the customer.

PARTS RETURN POLICY

Fuel Pro 482 Technical Manual

Documents