Davco fuel pro 382 Technical Manual
TABLE OF CONTENTS
Applications, Models, and Options.................. 1
How it Works................................... 1
“SEEING IS BELIEVING”
Dimensions and Specifications..................... 3
� Important Safety Precautions .................... 4
Installation Instructions ........................... 5
Installation Instructions - Diverter Cap............... 6
Coolant Heat Installation.......................... 7
®
........................ 2
12VDC and 24VDC Electric Pre-heater Installation
120VAC Electric Pre-heater Installation
.............. 9
..... 8
Water in Fuel Sensor (WIF) Installation .............. 10
Preventive Maintenance
......................... 11
Filter Change Procedure ......................... 12
Visual Diagnostics With Clear Cover................ 13
Visual Diagnostics - Air vs. Vapor Bubbles........... 14
Diagnostic Procedures - Air Leaks
. . . . . . . . . . . . . . . . . 15
Diagnostic Procedures - Heater Testing ............. 16
Check Valve Diagnostics......................... 18
Service Parts.................................. 19
Warranty Policy................................ 23
Parts Return Policy ............................. 24
FOR UPDATED INFORMATION, VISIT WWW.DAVCO.COM
F1271 REV J
2016 ©DAVCO Technology, LLC.
October 3, 2016 11:34 AM
FUEL PRO® 382
Technology, LLC
APPLICATIONS, MODELS, AND OPTIONS
Applications
Heavy duty engines with fuel flow up
to 180 GPH
Cold Weather Solutions
• 12VDC Pre-heater — Uses ignition switch to heat up fuel prior to
running the engine
• 120VAC Overnight heater — Prevents gelling while parkedovernight
• Coolant heat — Keeps fuel heated
while operating on highway
HOW IT WORKS
TECHNICAL MANUAL
Models and Options
• Base Model - Unheated
• Coolant Heat
• Electric Pre-heater Options (Heaters can be combined)
• 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 with low restriction.
• Clean, water-free fuel exits the Fuel Processor and flows to the engine fuel injection system.
DAVCO Technology, LLC P. O. Box 487 Saline, MI 48176 Call 800-328-2611 www.davco.com F1271 REV J
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FUEL PRO® 382
Technology, LLC
TECHNICAL MANUAL
“SEEING IS BELIEVING”®
• 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.
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 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 restriction levels. The filter still has significant life remaining.
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.
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.
DAVCO Technology, LLC P. O. Box 487 Saline, MI 48176 Call 800-328-2611 www.davco.com F1271 REV J
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2.5
Differential Pressure (in-Hg)
FUEL PRO® 382
Technology, LLC
DIMENSIONS AND SPECIFICATIONS
SERVICE HEIGHT
1.5 (38.1)
3.28 (83.3)
16.25 (412.8) MAX
1/2" x 14 NPTF
FUEL OUTLET
3.9 (99.1)
1/2" x 14
NPTF
FUEL INLET
Ø .43 (11.0)
(2 PLACES)
6.75 (171.5) MAX
FUEL
IN
TECHNICAL MANUAL
5.91 (150.0)
6.58 (167.1)
.50 (12.7)
Specifications
Height Overall 16.25 in (412.8 mm)
Depth Overall 6.58 in (167.1 mm)
Width, max. 7.3 in (185.2 mm)
Mount Bracket Centers 5.91 in (150 mm)
Weight, dry 8-12 lbs
Fuel In Connection 3/4"-14 NPTF
Fuel Out Connection 3/4"-14 NPTF
Filter Service Clearance Min
Max Fuel Flow 180 gph
Electric Pre-heater 12VDC, 250 W, 18 A
Fluid Heat Connection 3/8"-18 NPTF
1.5" (38 mm)
24VDC, 250 W, 12 A
120VAC, 75 W, .65 A
3.46 (88.0)
All dimensions are in inches (millimeters)
Filtration Performance at 100 GPH (EST.)
Micron Coarse
Water
Removal
(%)
7 mic
10 mic
25 mic
99.4 80.5 70
99.9 95.5 85
99.6 97.8 110
50 mic 97 <20 90
Emulsified Water
Removal (%)
Dirt Holding
Capacity (grams)
Restriction vs. flow
2.0
1.5
1.0
0.5
0.0
Differential Pressure (in-Hg)
0 20 40 60 80 100 120 140 160 180 200
Flow (gph)
7 micron
10 micron
25 micron
50 micron
DAVCO Technology, LLC P. O. Box 487 Saline, MI 48176 Call 800-328-2611 www.davco.com F1271 REV J
Flow (gph)
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October 3, 2016 11:34 AM
FUEL PRO® 382
Technology, LLC
TECHNICAL MANUAL
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 temperature 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 dispose of engine fluids, filters, and other contaminated materials according to applicable regulations.
DAVCO Technology, LLC P. O. Box 487 Saline, MI 48176 Call 800-328-2611 www.davco.com F1271 REV J
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October 3, 2016 11:34 AM
FUEL PRO® 382
Technology, LLC
INSTALLATION INSTRUCTIONS
Installation Location
The Fuel Pro must be installed between the fuel tank and
the fuel transfer pump. In some cases, the Fuel Pro can be
used as the only fuel filter in the system. This is generally
dependent on the engine model year. Consult the engine
manufacturer for their recommendation. If the Fuel Pro can
be used as a single filter, DAVCO offers a diverter cap to
replace the secondary filter. (See diverter cap installation
section)
Mounting the Fuel Pro
Mount the Fuel Pro keeping the following points in
mind:
• Do not install the Fuel Pro directly on the engine.
• Mount vertically with the cover and element pointing
up.
• Make sure there is enough top and side clearance for
the cover to be conveniently removed for filter replacement.
• The Fuel Pro MUST be installed so that the Filter Element is above the "FULL" level of the fuel tank.
� 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. Chock the
wheels.
1. With the engine shut down and at ambient temperature,
close the fuel shutoff valve (if equipped) and place a
suitable container under the fuel filters.
2. Remove the primary fuel filter element assembly, sedimenter, and/or water separator. Drain the used element
and dispose of it in an environmentally responsible
manner, according to state and/or federal (EPA) recommendations.
TECHNICAL MANUAL
Fuel Line Routing
To minimize fuel system restriction, observe the following guidelines when plumbing the fuel system:
• Keep the fuel line routing as smooth as possible with
no low-hanging loops which can trap water.
• Use 90° elbows only when necessary.
• If the fuel hoses are cut to length on the job, be sure
that the inner liner of the fuel hose is not cut by the fitting, which can cause check valve performance issues.
Make sure hoses are clean and free of debris before
installing.
• To avoid damaging the aluminum Fuel Pro body, do not
overtighten fuel lines or fuel line fittings.
1. Route the fuel supply line from the pick up on the fuel
tank to the Fuel Pro inlet (labeled “Fuel In”).
2. Route the fuel outlet line from the Fuel Pro outlet (labeled “Fuel Out”) to the inlet of the fuel pump.
Priming the Fuel System
1. Check to make sure the drain valve at the base of the
Fuel Pro is closed.
2. Remove the vent cap from the top of the clear cover.
Fill the Fuel Pro full with clean fuel. Reinstall the vent
cap. Tighten the vent cap by hand until it clicks.
3. Start the engine. When the lubrication system reaches
its normal operating pressure, increase engine RPM to
high idle for one to two minutes. After the air is purged
loosen the vent cap until the fuel level lowers to just
above the collar. Tighten the vent cap by hand until it
clicks.
4. 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 Pro and hand
tighten the collar until it no longer spins freely. Torque
the cover assembly by rotating the collar clockwise
three additional ribs using the collar wrench (~18 ft-lbs).
Note: The clear filter cover will not fill completely during
engine operation. It will gradually fill over time and the fuel
level will rise as the filter becomes contaminated.
DAVCO Technology, LLC P. O. Box 487 Saline, MI 48176 Call 800-328-2611 www.davco.com F1271 REV J
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October 3, 2016 11:34 AM
FUEL PRO® 382
Technology, LLC
INSTALLATION INSTRUCTIONS - DIVERTER CAP
Diverter Cap Installation
If a single fuel filter system is approved by the engine
manufacturer, the following steps are to be taken to install a
diverter cap properly.
1. Select the required secondary filter head diverter cap
from those listed in Table 1. The required diverter cap is
determined by the size of the spin-on filter stud and the
filter sealing surface diameter.
2. Drain and remove the secondary fuel filter element.
3. Lightly lubricate the seal on the top of the diverter cap
with clean engine oil.
4. Thread the adapter onto the secondary filter stud and
tighten.
5. Install the “Do Not Remove” label on the diverter cap.
TECHNICAL MANUAL
Diverter Cap
Part Number
101480 1"-14
101589 1"-14 3.225" 3.435"
101570 M16 x 1.5 2.475" 2.895"
101466 ¾"-16 2.475" 2.895"
101492 7/8" x 14 2.475" 2.895"
Required
Filter Head
Stud Size
Table 1
Required
Filter Head
Seal ID
2.475" 2.895"
Required
Filter Head
Seal OD
DAVCO Technology, LLC P. O. Box 487 Saline, MI 48176 Call 800-328-2611 www.davco.com F1271 REV J
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October 3, 2016 11:34 AM
FUEL PRO® 382
Technology, LLC
COOLANT HEAT INSTALLATION
Most truck OEMs currently offer engine return fuel as the
heat source for the DAVCO Fuel Pro 382. Current common
rail engines generally do not have enough return fuel heat
or flow rate to be used as a heat source for Fuel Pros. To
address this, a DAVCO Fuel Pro 382 can be easily plumbed
for engine coolant to provide adequate heat at the primary
filter (Figure 2).
TECHNICAL MANUAL
Determine if the bottom plate is equipped with a fluid heat
assembly. (Figure 3) If the Fuel Pro 382 has a deep bottom
plate it is a heated assembly with a heater loop and can
be upgraded to use coolant heat.(Refer to form F3029 on
www.davco.com for upgrade instructions).
If the bottom plate is flat, order the DAVCO fluid heat bottom plate upgrade kit, DAVCO P/N 382029-23DAV.
Figure 2
Fluid heat bottom plate
Flat Bottom Plate
Figure 3
DAVCO Technology, LLC P. O. Box 487 Saline, MI 48176 Call 800-328-2611 www.davco.com F1271 REV J
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October 3, 2016 11:34 AM
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