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Summary of Contents for Fass 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 Building extremely “High-Quality” fuel products is our business. We concentrate all of our efforts in this arena. No one else is as specialized as FASS in what we do! This is one of the ingre- dients to insure you are running with the “Highest-Quality” fuel system in the world! We have im- plemented very rigorous testing procedures to provide the “Highest Quality”...
- Page 3 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 call FASS for technical assistance. Be sure to utilize the inline fuel filter included in this kit, or the equivalent, to prevent a ...
- Page 4 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.
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Page 5: Installation
Adjustable Fuel Pump Series 220 or 240 GPH 45 PSI (Approximately) A fuel pressure gauge is highly recommended to identify fuel filter life and to prevent engine damage! Adjustment Lock Nut Set screw Boost Compensation Port ‘T’ Fuel Inlet Port “E”... - Page 6 Contents THB-1001 BHB-1001 FF-3248 MP-9037 FPB-2005 WH-1005 FL-1002 x14’...
- Page 7 Mounting Package Contents *Cable Ties* RS-1002 BHF-1002 PL-1005 DIPF-1003 10-300 PL-2003 46260 46044 Ring Terminal 1/2” Plug PL-1004 BHN-1001 LW-1001 OR-223 HC-1001 ST-1005Px16” 1/4” Nut 1/4” washer RS-2001 1/4 - 20x1.5” 1/4 - 20x1.75”...
- Page 8 The installation of the electrical harness is done first, allowing power to be applied to the pump for lubrication purposes later in the installation. Using wire stripping tool remove excess insulation off the add-a-fuse and the WH-1005. Place wire from 46044 and WH-1005 into butt connector. Using crimping tool connect 46044 and WH- 1005 with butt connector.
- Page 9 E. If fuse panel is located in the cab it will be necessary to guide the single red wire from the relay through the fire wall grommet to access the fuse pan- Locate fuse box under hood and select ignition hot fuse. Remove fuse and put Add-A-Fuse in place. Install fuse previously removed.
- Page 10 Some of the photo’s are of a different application, procedures are the same. NOTE: Before installing fittings make sure to inspect for burs or flare imperfections. When cutting fuel line make sure to blow out line to keep debris from moving forward. Very Important: Before removing the fuel tank, identify “ALL”...
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Page 11: Very Important
Assemble the BHF-1002 with the PL-1004 in port “S” using thread tape, the 1/2” plug in port “R” along with pushing the ST-1005P onto the barb portion of the BHF-1002. Insert O-ring into groove. Torque to 40ft/lbs. Before drilling marked location, clean area of debris. Using the photo, double check area selected for any interference including the fuel level Drill a 1 3/8”... - Page 12 Route fuel line over the frame rail while reinstalling the fuel tank. Torque tank hanger bolts to proper specifications. Connect factory wire harness to the fuel module along with the factory fuel lines. FASS harness Reattach filler neck and clamps.
- Page 13 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 Note: Do Not Put Thread Tape on Flare of Fitting initial priming.
- Page 14 Slid the FASS pump into mounting brackets with the weep hole facing down. Torque (4) 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 Do Not use sealant on AN (male flare) fittings. Only use sealant on threads installed into pump assembly. Route fuel line to the suction port on the FASS pump labeled “T”. Cut the fuel line. Insert PL-1005 into fuel line using oil. At- tach to 10-300 in ‘T’...
- Page 16 Attach the PL-2003 to DIPF-1003. Torque to 18 ft./lbs. Remove banjo bolt connecting the outlet line of the factory fuel filter. This is the line in front of the inlet line removed in step f. 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.
- Page 17 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. ...
- Page 18 Disclaimer: 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.
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