Fuel PRO
Fuel PRO
Fuel PRO
Filter/Separator/Warmer
Installation Instructions
Standard and Plus Series
1
! CAUTION: These instructions are intended for use by professional mechanics who are trained in the proper use of power and hand
tools, using appropriate safety precautions (including eye protection).
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EXT Series
A Part
Part Description Number
E F
G H
I
J
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Step 5 - Route the fuel supply line from the fuel tank to
WIF Probe
the Fuel Pro inlet (Figure 1). Route a fuel line from the Fuel
WIF Location
Pro outlet to the fuel pump inlet.
EXT
Note: Use appropriate connectors to attach the 1. Drain all fuel from the Fuel Processor. Dispose of the fuel
wires. To test the WIF indicator, pour water into in an enviromentally responsible manner.
the body of the fuel processor until it covers the
WIF probe. The WIF LED should illuminate. For 2. Disconnect and remove the chassis harness,
unheated fluid, the volume of fluid necessary to thermoswitch, and heater. (If necessary, remove the
turn the WIF indicator on is 6.15 oz ± .07 oz bottom plate from the unit for ease of assembly/
(182 mL ± 2 mL), for heated fluid the volume disassembly).
necessary is 3.08 oz ± .07 oz (91 mL ± 2 mL). 3. Apply pipe sealant to threads of pipe plug and the new
Fuel Heating Options pre-heater and install into the bottom plate. If the bottom
plate was removed, replace the seal (round style for
Note: The Engine Return Fuel Heat and Engine bottom collar, square style for bolt-on) and reinstall.
Coolant Heat options apply ONLY to the heater Torque bottom collar to 50-6- ft-lbs or screws to 10-12
base shown in Figure 4. If the bottom plate is flat ft-lbs.
with 1/2" NPT ports, only the Electric Preheater 4. Connect the pre-heater harness to the chassis power
can be used.
connector.
Engine Return Fuel Heat 5. Start engine, when the lubrication system reaches normal
operating pressure, increase the RPM for one minute.
Electronic unit injected engines can use return fuel Slowly open vent cap until fuel level drops to one inch
as the fluid heat for the Fuel Pro. Route the return above collar. Hand tighten vent cap. See Table 2 for
fuel line from the engine into the Heater Base of the heater kits.
Fuel Pro (see Figure 4). Either heater port will work Table 2 - 12 V & 24 V Heater Units
as an inlet. Connect a second fuel return line from
the Heater Base to the fuel tank return port. Part Number Description
SP1319 Pre-Heater, 24 V, 195 W, Weather-Pack Connector
SP1320 Pre-Heater, 12 VDC, 195 W, Metric-Pack Connector
SP1321 Pre-Heater, 12 V, 195 W, Weather-Pack Connector
SP1322 Pre-Heater, 12 V, 195 W, Weather-Pack Connector
3945121 S 120 VAC, 75 W Overnight Heater
Fuel or
Engine Coolant Note: 25 A fuse is recommended but not included in Fuel Pro kits
Fuse Connection
Key Controlled Thermo-Switch
Step 3 - Using the Collar Wrench (part number 3944451 S
Switch (composite) Figure 7, 3944448 S (metal) Figure 8, or SP1076
– + for EXT series), remove the clear cover from the fuel processor
Battery 25 A Heater by removing the collar. Discard the o-ring from the base of the
Fuse
cover. (A new o-ring seal is supplied with the new filter.) For
Biodiesel applications use gasket pack 3950445 S. Gasket color
Relay Relay Connection is green and MUST be changed with every filter change. Remove
the filter element from the Fuel Pro by pulling upward and
87A
twisting slightly. Be sure the sealing grommet is removed from
87
Battery
the center stud.
86
85
30/51 COLLAR
FUEL PRO
VENT
CAP
Two types of cordsets are available for the 120 V heater. See
Table 3 and Figure 6 for cordset information.
120 V, 15 A
Part Number Plug
3945126 S 6 in.
Y Cordset
84" (213.3 cm)
120 V, 15 A
Plug Figure 8 - Metal Collar Wrench
Part Number Step 4 - Install a new filter, cover seal and vent cap seal. Reinstall
3946716 S
120" (304.8 cm) the clear cover and collar. Simutaneously apply downward
pressure to 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
Figure 6 - Electric Heater Cordsets freely. Torque the cover assembly by rotating the collar clockwise
Filter Change Procedure (~18 ft-lbs)
Step 5 - Remove the vent cap from the top of the clear cover by
Step 1 - Turn off the engine. Loosen the vent cap to break the turning the vent cap counterclockwise. Fill the clear cover with
air lock in the filter. enough clean fluid to cover the bottom half of the filter element.
Make sure the new o-ring (supplied with the filter) is installed on
Step 2 - Open the drain valve and drain the fuel level below the the vent cap. Reinstall the vent cap and tighten by hand only.
collar, then close the drain valve. Dispose fuel and filter in an
enviromentally safe manner, according to state and/or federal Step 6 - Start the engine. When the lubrication system reaches
(EPA) recommendations. its normal operating pressure, increase the engine RPM for one
minute.
Page 7
Step 2 - Remove the vent cap from the top of the clear cover.
Fill the Fuel Pro full of clean fuel. Reinstall the vent cap and Suggested Preventive Maintenance
tighten by hand only.
Weekly - Drain water.
Every Filter Change - Change o-rings and grommet
Step 3 - Start the engine. When the lubrication system reaches
(included with new filter).
it's normal operation pressure, increase engine speed to high
Every 12 Months - Check all electrical connections
idle for one to two minutes. After the air is purged, loosen the
for corrosion. Check all fuel fitting for leaks.
vent cap until the fuel level lowers to just above the bottom of the
collar. Tighten the vent cap by hand only.
Extreme winter or salt corrosion enviroments may
require lubrication of the top collar threads with
Note: The clear filter cover will not fill completely
Loctite® 76747 antiseize every 180 days.
during engine operation. It will gradually fill over
time as the filter becomes clogged.
Ordering Information
Housing Part
Filter Element** Size Pre-Heater 1 Pre-Heater 2 Fluid Heat WIF Fuel Flow
Number
FH23027 FS19763 Plus 12 VDC 120 VAC Yes No In Right / Out Left
FH23028 FS19763 Plus 24 VDC 120 VAC Yes No In Right / Out Left
FH23029 FS19763 Plus N/A N/A N/A No In Right / Out Left
FH23030 FS19905G Plus N/A N/A N/A No In Right / Out Left
FH23031 FS19763 Plus 12 VDC N/A N/A No In Right / Out Left
FH23032 FS19763 Plus 24 VDC N/A N/A No In Right / Out Left
FH23038 FS19763 Plus N/A N/A Yes No In Right / Out Left
FH23039 FS19763 Plus N/A N/A Yes Yes In Right / Out Left
FH23040 FS19763 Plus 12 VDC N/A Yes No In Right / Out Left
FH23041 FS19763 Plus 12 VDC N/A Yes Yes In Right / Out Left
FH23042 FS19763 Plus 24 VDC N/A Yes No In Right / Out Left
FH23045 FS19763 Plus 120 VAC N/A Yes No In Right / Out Left
FH23048 FS19728 Plus 24 VDC 120 VAC N/A Yes In Right / Out Left
FH23049 FS19763 Plus 12 VDC N/A N/A Yes In Right / Out Left
FH23050 FS19763 Plus 24 VDC N/A N/A Yes In Right / Out Left
FH23054 FS19763 Plus 12 VDC 120 VAC N/A No In Right / Out Left
FH23060 FS19765 Plus N/A N/A N/A Yes In Right / Out Left
FH23061 FS19763 Plus N/A N/A N/A Yes In Right / Out Left
FH23067 M* FS19765 Plus 24 VDC N/A N/A Yes In Right / Out Left
FH23068 M* FS19765 Plus Ports Available N/A N/A Yes In Right / Out Left
FH23069 M* FS19765 Plus 24 VDC N/A Yes Yes In Right / Out Left
FH23076 FS19763 Plus N/A N/A N/A No In Right / Out Left
FH23100 FS19915 EXT N/A N/A N/A No In Left / Out Left
FH23127 FS19764 Plus 12 VDC N/A N/A Yes In Right / Out Left
FH23128 FS19765 Plus 12 VDC N/A N/A Yes In Right / Out Left
FH23129 FS19905G Plus N/A N/A N/A Yes In Right / Out Left
FH23130 FS19764 Plus N/A N/A N/A Yes In Right / Out Left
FH23131 M* FS19764 Plus Ports Available N/A N/A Yes In Right / Out Left
FH23166 FS19915 EXT 24 VDC N/A N/A Yes In Right / Out Left
Dimensions
Standard and Plus Series
Front Right Side Back
3.28 3.90 7.30
(83.3) (99.1) (185.2)
Service Height
3.5 (88.9)
16.00
(406.4)
1/2-14
NPTF
.97
Fuel 1/2-14
(24.6)
Outlet NPTF
Fuel
Inlet
ø.43
(11.0)
(2 places)
5.10
(129.5)
3.46
5.91 (88.00)
(150.0)
Bottom
6.58
(167.1)
8.34 MAX
(211.8)
12.13
(308.1)
MAX
FUEL IN
14.28
1/2"-14 NPTF
(362.7)
FUEL OUT MAX
1/2"-14 NPTF
FUEL
OUT
2.06 1.94 .47 .47
2.95 (52.3) (49.2) (11.9)
.75 (11.9)
(74.9) 1.20
(1.91) (30.5)
1.12 .70
(28.4) (17.8) Note:
2.26 2.50 This drawing
(57.4) (63.5)
reflects the left
RIGHT
side Fuel In/Fuel
LEFT
Out configuration.
Fuel In is also
3.75 available on the
(95.3)
MAX right side.
1"-14 UN
120V-75
19.81
2.26 2.26 (503.2)
(57.4) (57.4) MIN
.50
3.70 (12.7)
.99 1.36
(94.0)
(25.1) (34.5)
FUEL OUT
2.32
2.27 4.21 MIN (59.0)
(57.7) (106.9)
FUEL IN
Specifications
Specifications Standard and Plus EXT
Overall Height 16.13" 14.28" (362.7 mm)
Overall Depth 7.25" 6.58" (167.13 mm)
Maximum Width 6.89" 8.35" (211.8 mm)
Mount Bracket Centers 5.91" 3.94" (100.0 mm)
Dry Weight 7.25 - 9.75 lbs 10.35 lbs
Fuel In Connection 1/2"-14 NPTF (M22 x 1.5) 1/2"-14 NPTF (M22 x 1.5)
Fuel Out Connection 1/2"-14 NPTF (M22 x 1.5) 1/2"-14 NPTF (M22 x 1.5)
Fluid Heat Connection (Inlet) 3/8"-18 NPTF (M14 x 1.5) 1/2"-14 NPTF (M22 x 1.5
Fluid Heat Connection (Outlet) 3/8"-18 NPTF (M14 x 1.5) 1/2"-14 NPTF (M22 x 1.5
Fuel Capacity (w/filter) 64.2 fl oz (1.9 L) 110.2 fl oz (3260 ml)
Recommended Applications Heavy Duty Engines
Water Trap Capacity 33.8 fl oz (1.0 L) 20.29 fl oz (600 ml)
Filter Service Clearance Min 1.5" (38.1 mm) Min. 3.50" (88.9 mm)
Operation Fuel Flow Rate 180 gal/hr (681 L/hr) 180 gal/hr (681 L/hr)
12 VDC, 195 W, 8.5 A +/-0.8 12 VDC, 195 W, 8.5 A +/-0.8
Electric Pre-heater 24 VAC, 195 W, 4.5 A +/-0.4 24 VAC, 195 W, 4.5 A +/-0.4
120 VDC, 75 W, 0.63 A ± 0.1 120 VAC, 75 W, 0.63 +/_0.1
Fuel Types Compatible for use with #1 Diesel, #2 Diesel, Kerosene, Biodiesel, and JPS
Performance
10 2.5
5HVWULFWLRQYVġRZ
1.4
Differential Pressure (in-Hg)
Restriction (psi)
1.0
6 1.5
FS19763 0.8
1.0
4 0.6
0.4 0.5
2
0.2
0.0
0 0.0 0 25 50 75 100 125 150 175 200 225
0 2 4 6 8 10 12 Flow (gph)
Flow (L/min)
Page 12
Revisions
Revision Date Description
9 10/18/2017 Added "Standard, Plus, and XLT" series to differentiate between product sizes. Renamed Instructions to Fuel Pro Series from
FH23 Series.
10 12/04/2017 Updated Vent Cap - SP1053 was 3944440 S, SP1321 was 3959753 S, SP1319 was 3952119 S, Diverter Cap 3945185 S was
3945485 S,
Electric Heater Upgrade Kits was Optional Preheater steps, Revised heater information in Table 2,
Composite Collar Wrench was Collar/Vent Cap Wrench, Added Metal Collar Wrench - Figure 8,
Revised Step 4 in the Filter Change Procedure,
Revised descriptions on replacement filters FS19761 and FS19766 to 5 micron from 2 micron.
Removed duplicate Caution note.
Revised graphics for the Dimension Standard and Plus to show current vent cap.
Added FH23048 and removed FH23082M and FH23072GM in ordering information.
11 01/18/2018 FH23030 filter element FS19905G Plus was FS19729 Standard, FS19905G was FS19729, EXT was XLT in all instances
12 02/05/2019 Removed Port and Plug from FH2316600 (EXT) Housing.
13 01/06/2020 WIF 3957158 S was 3977418 S, Removed FH23132M from Ordering Information