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Summary of Contents for Fass HEAVY DUTY HD D07 220G
- Page 1 INSTALLATION MANUAL APPLICATION: HD D07 220G (220gph @ 16psi) (or 50psi) Cummins 5.9L /6.7L 2005-2012 *1998.5-2004 With In-tank Lift Pump*...
- 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 ¡WARNINGs! Read all instructions before starting installation of this product! Installing the improper FASS Pump can cause severe engine damage. FASS Recommended Application HD D07 220G Cummins 2005-2012 with super extreme horsepower modifications Note: This kit may also be used on 1998.5-2004 Cummins with in-tank lift pump...
- Page 4 4. For best results in accuracy and efficiency (due to training, communication, and our relationship with our dealer network), we recommend an Authorized or ViP FASS Fuel Systems dealer for the installation. They are prepared to install the FASS fuel pumps with the most efficiency. If a situation/problem arises during the installation, they are the most prepared for that situation/problem.
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Page 5: Installation
Heavy Duty Series 220 GPH 16 PSI (Approximately) A fuel pressure gauge is highly recommended to identify fuel filter life and to prevent engine damage! Installation Step 1: Install Electrical Harness Step 2: Prepare Suction and Return Lines Step 3: Mount Fuel System Step 4: Install Fuel Line... - Page 6 Contents MP-9014 WH-1004 FB-1001 FL-1002 x17‟ BR-2001...
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Page 7: Mounting Template
Mounting Package Contents RS-1001 BHF-1002 ST-1005P x14” PL-2003 10-300 DIPF-1003 PL-1005 PL-1004 10-301 WA-1001A WA-1001B 2 Hex Bolt 1/4”-20x1” 3 Hex Bolt 1/4”-20x1.5” 7 Locking Nut 3/8” 7 Hex Bolt 3/8” -16x 1 1/4” Mounting template Ring Terminal BHN-1001 LW-1001 OR-223... - Page 8 Step 1: Install Electrical Harness Note: The installation of the electrical harness is done first, allowing power to be applied to the pump for lubrication purposes. Fuse a. Using ring terminals, attach red wire of the WH-1004 to the positive battery Neg.
- Page 9 Step 2: Preparing Suction and Return Line Very Important: Before removing the fuel tank identify “ALL” areas of clear- ance between the tank and bed to install the draw tube assembly. 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! Helpful Hints: If more space is required to access the top of the fuel tank, loosen the strap nuts to the end of the stud.
- Page 10 STEP 2: Prepare Suction & Return Lines, Continued h. Before drilling marked location, clean area of debris. Using the photo double check area selected for any interference including the fuel level arm. i. Drill a 1 1/2” hole, catching all debris. De-bur hole and remove any missed debris in the fuel tank.
- Page 11 Torque tank hanger bolts to proper specifications. Factory harness p. Connect WH-1004 (addressed in Step 1) to the fuel module along with the fac- tory fuel lines q. Connect factory wire harness to the WH-1004. FASS harness r. Reattach filler neck and clamps.
- Page 12 Attach BR-2001 to back of system using 2 - 1” & 3 - 1.5” Hex bolts with 2 - WA-1001A & 3 - WA-1001B spacers. Torque to 110 in./lbs. c. Assemble the FASS pump brackets using the RS-1001 spacer between. Hold pump up to the mounting location for rough fitting. Once location is established, use template located on the contents page to accurately mark drill points.
- Page 13 Step 3: Mount Fuel System, Continued f. Connect factory plug into the FASS harness. Plug FASS harness into the fuel module in tank. Make sure to lock red slide tab. Connect female plug of the FASS harness into pump. Turn key to “on”. With pump operating (you may have to bump the starter), turn pump over, liberally spray WD-40 (or equivalent) into water separator nipple lubricating Gerotor.
- Page 14 Use oil. Attach fitting to the „R‟ port. Torque to 18 ft/lbs. c. Insert PL-1005 in remaining fuel line. Connect to the „E‟‟ port of the FASS system. Use oil. Torque to 18 ft./lbs. Route this line up to the injection pump.
- Page 15 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. 2. While the pump is running, loosen the fuel filter just enough to break the gasket seal. Once the tone of the pump changes, quickly retighten filter.
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