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DIESEL PRO
243 TECHNICAL MANUAL
®
TABLE OF CONTENTS
Applications, Models, and Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
How it Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
®
Dimensions and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Important Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Priming the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Water-in-Fuel (WIF) Sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
120VAC Overnight Heater Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
12 or 24VDC Pre-heater Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Visual Diagnostics-Air vs . Vapor Bubbles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Diagnostic Procedures for Air Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Visual Diagnostics with Clear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Diagnostic Procedures For Pre-heater/Overnight Heaters . . . . . . . . . . . . . . . 12
Filter Change Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Check Valve Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Service Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Warranty Policy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Parts Return Policy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
FOR UPDATED INFORMATION VISIT WWW.DAVCO.COM
F1215 REV H
2019 ©DAVCO Technology, LLC . Last updated 12-12-2019
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Summary of Contents for Davco DIESEL PRO 243
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Page 1: Table Of Contents
Parts Return Policy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 FOR UPDATED INFORMATION VISIT WWW.DAVCO.COM F1215 REV H 2019 ©DAVCO Technology, LLC . Last updated 12‑12‑2019... -
Page 3: Applications, Models, And Options
Clean, water‑free fuel exits the Diesel Pro and flows to the engine fuel injection system . Fuel System Diagram FUEL TO TANK FUEL FROM TANK www. ENGINE LIFT PUMP FUEL TO ENGINE FUEL TANK DAVCO Technology, LLC 1600 Woodland Drive, Saline, MI 48176-1629 800-328-2611 www.davco.com F1215 REV H... -
Page 4: Seeing Is Believing
Restriction is increasing and the filter element should be taining lowest restriction . changed at the next scheduled maintenance interval . DAVCO Technology, LLC 1600 Woodland Drive, Saline, MI 48176-1629 800-328-2611 www.davco.com... -
Page 5: Dimensions And Specifications
120VAC 75W PORT INTERFACE Fuel In Connection ⅜"‑18 NPTF or ½"‑14 NPTF Fuel Out Connection ⅜"‑18 NPTF or ½"‑14 NPTF 125 150 175 200 Flow (gph) DAVCO Technology, LLC 1600 Woodland Drive, Saline, MI 48176-1629 800-328-2611 www.davco.com F1215 REV H... -
Page 6: Important Safety Precautions
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 for a replacement . • Refer to appropriate regulations for environmental and workplace safety rules . -
Page 7: Installation Instructions
FUEL OUT right use only one inlet and one outlet Mount the Diesel Pro in the desired location using ⅜" port per installation . Grade 8 bolts . FUEL IN FUEL OUT LEFT SIDE RIGHT SIDE DAVCO Technology, LLC 1600 Woodland Drive, Saline, MI 48176-1629 800-328-2611 www.davco.com F1215 REV H... -
Page 8: Priming The Fuel System
Remove the WIF or the plug . Install the WIF into the WIF port . Torque to 45‑60 in .‑lb . WIF PORT Prime the Diesel Pro (see page 6) and check for leaks . DAVCO Technology, LLC 1600 Woodland Drive, Saline, MI 48176-1629 800-328-2611 www.davco.com... -
Page 9: 120Vac Overnight Heater Installation
Connect the cord to a 120VAC output location on the truck (usually located below the driver’s door) . Prime the Diesel Pro (see page 6) and check for leaks . DAVCO Technology, LLC 1600 Woodland Drive, Saline, MI 48176-1629 800-328-2611 www.davco.com... -
Page 10: 12 Or 24Vdc Pre-Heater Installation
. Pre‑heater Wiring with Relay Harness Heater Connector Pre-heater Fuse 12/24VDC 30/51 Ignition 30/51 Circuit OPTIONAL Fuse RELAY Ignition Switch DAVCO Technology, LLC 1600 Woodland Drive, Saline, MI 48176-1629 800-328-2611 www.davco.com F1215 REV H... -
Page 11: Visual Diagnostics-Air Vs. Vapor Bubbles
FUEL RETURN FUEL RETURN ENGINE ENGINE LIFT PUMP LIFT PUMP LIFT PUMP LIFT PUMP FUEL FUEL TANK TANK AIR BUBBLES VAPOR BUBBLES Figure 1 Figure 2 DAVCO Technology, LLC 1600 Woodland Drive, Saline, MI 48176-1629 800-328-2611 www.davco.com F1215 REV H... -
Page 12: Diagnostic Procedures For Air Leaks
If fuel flows out of the unit, follow the check valve testing tact . Use a DAVCO wrench (if necessary) procedures on page 15 . to tighten the collar three additional ribs . -
Page 13: Visual Diagnostics With Clear Cover
Fuel level is at the top of the filter and appears to be full of wax . ÎChange the filter . Run the engine for a minimum of 25 minutes at idle . Do not run at full RPM . DAVCO Technology, LLC 1600 Woodland Drive, Saline, MI 48176-1629 800-328-2611 www.davco.com... -
Page 14: Diagnostic Procedures For Pre-Heater/Overnight Heaters
0 .4 to 0 .6 @ 77°F (25°C) 24VDC 195W 2 .0 to 3 .0 @ 77°F (25°C) 12VDC 155W 0 .95 to 1 .2 @ 77°F (25°C) DAVCO Technology, LLC 1600 Woodland Drive, Saline, MI 48176-1629 800-328-2611 www.davco.com F1215 REV H... -
Page 15: Filter Change Procedure
“CHANGE FILTER” lettering on the cover . three additional ribs ( . . For filter selection visit www .davco .com for the correct filter for your application or call DAVCO Customer Service at Prime the Diesel Pro (see page 6) and check for leaks . -
Page 16: Preventative Maintenance
Inspect all electrical connections and housing for corrosion . • Inspect all fuel fittings for leaks . • Inspect the Diesel Pro for damage or signs of leaks . DAVCO Technology, LLC 1600 Woodland Drive, Saline, MI 48176-1629 800-328-2611 www.davco.com F1215 REV H... -
Page 17: Check Valve Service
Install the clear cover and collar . Apply downward pressure on the top of the cover and rotate the collar until contact . Use a DAVCO wrench (if necessary) to tighten the collar three additional ribs ( . . DAVCO Technology, LLC... - Page 18 25 Micron EleMax Filter, Fleetguard Contact DAVCO Customer Service for OEM Part Numbers. *For filter selection visit www .davco .com for the correct filter for your application or call DAVCO Customer Service at 800‑328‑2611 . DAVCO Technology, LLC 1600 Woodland Drive, Saline, MI 48176-1629 800-328-2611 www.davco.com...
- Page 19 12VDC 155W PTC Pre‑heater, Metri‑Pack Connector, ⅞"‑14 UNF Threads, Harness Length 7 .50" (Freightliner) 102376DAV Pre‑heater Chassis Harness, Metri‑Pack Connector 102220DAV Pre‑heater Chassis Harness, Weather Pack Connector DAVCO Technology, LLC 1600 Woodland Drive, Saline, MI 48176-1629 800-328-2611 www.davco.com F1215 REV H...
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Page 20: Service Part Numbers
Two Pin WIF, Yazaki Connector, ½"‑20 UNF Threads, Harness Length 20 .94" (Hino) 102600DAV Two Pin WIF Wiring Harness (Used with 102512 and 102521DAV) Deutsch Connector DAVCO Technology, LLC 1600 Woodland Drive, Saline, MI 48176-1629 800-328-2611 www.davco.com F1215 REV H... -
Page 21: Warranty Policy
® DAVCO Technology, LLC warrants the Shop Pro (except for the motor) to be free of defects in material and workmanship for two years from the date of purchase . The Shop Pro motor is warranted for one year from date of purchase . -
Page 22: Parts Return Policy
T e c h n o l o g y , L L C PARTS RETURN POLICY Parts Return General Policy A Return Goods Authorization (RGA) must be obtained from DAVCO prior to returning any products . Returns may be accepted under the following circumstances: •...