Horizon Fuel Cell Technologies FASS-150, FASS-180-1010 User Manual

INSTALLATION MANUAL
FASS FUEL SYSTEM MODEL NO. FASS-150/180-1010@45psi

“HIGH PERFORMANCE FUEL DELIVERY SYSTEM”

FROM: Diesel Performance Products, Inc.
SUBJECT: Welcome/Thank You
TO: Valued Customer
We at Diesel Performance Products, Inc. (DPP) would like to thank you for your confidence in

purchasing one of the FASS Products. Building a quality product and providing excellent customer
service is # 1 at DPP. Behind each fuel system/fuel pump are many years of design experience. We
have implemented very rigorous testing procedures before bringing any item to the market along with
very strict manufacturing procedures to provide a superb product. Our confidence is evident in the
products we make as each product is backed by an industry leading warranty.

We, Diesel Performance Products, promote “ALL” retail business through our dealer network

to provide better customer service! We are confident that everyone involved is best serviced in this
manner. We have given our dealer network proper knowledge and support to promote and service our
line of products.

Dealers receive appropriate troubleshooting guides to refer to. These have proven to be
excellent references for those who choose to use them. We provide excellent assistance to our dealers
so they in turn can assist their customers. DPP has decided to place this information on our website to
accommodate all of our customers needs.

Our R & D Department in conjunction with our Dealer Support Department is continually
searching for ways to improve quality, expand our product line, and provide superb support to our
network of dealers so they can support their customers.

Please make sure to fill out your product registration form and return the original form to
Diesel Performance Products, Inc. within 30 days of purchase accompanied with a copy of the
purchase receipt. Doing so will qualify you for the Limited Lifetime Warranty!

Steps to customer satisfaction can be found on the next page.

2

STEPS TO CUSTOMER SATISFACTION

We want you to be happy with your FASS Fuel System. Customer satisfaction, your
satisfaction, is the all-important ingredient for success in our business, as it is in any other.

Normally, warranty problems can be resolved by your Dealer’s sales or service departments.
That’s why you should always talk to your Dealer’s Service department first. If you’re not satisfied
with the dealership’s response at this level, Diesel Performance Products, Inc. (DPP) recommends that
you follow these steps, in order:

STEP 1: Discuss the problem with the owner or General Manager of the dealership.

STEP 2: If your dealership in unable to resolve the problem, contact Diesel Performance

Products, Inc. Customer Care Center in writing; the address is located on page 14 of this
manual or fax it to 636-433-5913. Be prepared to provide the Customer Center with the
following information:

• Your Name, address and daytime phone number

• Model and Serial Number (Not Model Number)

• Dealer, contact name and phone number

• Date of purchase

• Nature of Problem

Once you have followed the two steps described, a DPP representative will review your situation.
DPP will then follow up by contacting the dealer for more information. Depending on the situation a
representative from the selling dealer or a representative of DPP may elect to contact you.

Thank you for your business, from the men and women of Diesel Performance Products, Inc.

3

FILTER CROSS REFERENCE SHEET

Cross Reference List for the FASS 150 Series Fuel Filter

Recommended Fuel

BRAND

FASS FF-1010 10 Stratapore™
FASS FF-1003 3 Stratapore™

CIM-TEK 70032 10 Microglass

CIM-TEK 70213 3 Microglass
Fleetguard HF6601 8 Cellulose/Synthetic

Fleetguard HF6610 16 Cellulose

Fleetguard HF6613 12 Microglass
Fleetguard HF6607 6 Microglass

Fleetguard HF6604 3 Microglass

Caterpillar 3T8642

Cross Reference List for the FASS 150 Series Water Separator

BRAND

FASS WS-1001 144 Stainless Steel/Water Separator

Fleetguard FS1023 144 Stainless Steel/Water Separator

Part # Micron Rating Material

Recommended Water

Part # Micron Rating Material

Stratapore™ or Microglass

Filter Media:

Stainless Steel/Water Separator

Filter Media:

NOTE: The use of a hydraulic fuel filter is because the canister is much thicker and

provides more durability than a fuel filter canister.

4

WARNING!!

Installing the improper FASS Fuel System or installation kit can cause severe engine
damage.

This installation manual applies to the FASS-150/180-1010@45psi contained in the
same package. The serial number on the installation/owners manual package should
match the serial number on the outside of the box. If it doesn’t, call the factory.

This FASS-150/180-1010@45psi (180gph):

Recommendation: FASS-150/180-1010@45psi - the Dodge Cummins Truck 1994-1998,

with extreme horsepower modifications.

SAFETY GUIDELINES AND WARNINGS!

TIP! Flush and clean all brass fittings and fuel line free from debris.
WARNING! SECURE VEHICLE FROM ROLLING!

WARNING! Use care not to drill into any electrical wires, air lines or other damageable

components when drilling.

WARNING! Consult vehicle manufacturer’s instructions concerning the electrical system

before attempting any electrical connections.

CAUTION: Wear safety glasses when operating power tools such as drills and grinders or

when using a punch or chisel.

CAUTION: Properly secure lines to prevent chaffing.

VERY IMPORTANT: THE RETURN FUEL FITTING LOCATED IN THE BASE OF THE FASS
FUEL SYSTEM SHOULD NOT BE REMOVED. THERE IS A SPECIAL CUT IN THIS FITTING
THAT ASSISTS IN REGULATING PRESSURE. ALSO, DO NOT REMOVE ANY STEEL ALLEN
HEAD FITTINGS. THESE PORTS WERE USED IN THE MACHINING PROCESS.

5

INSTALLATION MANUAL

Welcome to the FASS Fuel/Air Separation System.

The installation of the FASS FUEL SYSTEM can be relatively simple when the
following steps are followed.

1. Inventory the package components completely. Notify place of purchase
immediately of any parts missing or damaged.

2. We have invested many hours into the development of the installation and owner’s

manual’s to simplify the installation and operation of the FASS Fuel System. Please
read the owner’s manual and the installation manual completely before attempting
installation. Understand how the system operates and installation recommendations
before beginning installation. Most of the questions that you will have will be
answered in one of these manuals. If you have a question please review the
installation or owner’s manual.

3. The installation recommendations contained herein are suggested installation
guidelines only. Each installation can and may vary considerably because of the
many options and accessories available to the truck market.

Installation personnel should use good judgment and common sense when
installing the FASS Fuel System.

If any installation procedure is uncertain, contact place of purchase.

Due to training, communication and our relationship we have with our authorized
dealers we recommend an authorized FASS Fuel Systems dealer for the installation of
the FASS System. They are prepared to install the FASS System with the most
efficiency. If a situation/problem arises during the installation they are most prepared
for that situation/problem. It may take more time for an unauthorized shop to address
the situation/problem. We will not be responsible.

Please make sure to fill out your product registration form and return the original form to
Diesel Performance Products, Inc. within 30 days of purchase accompanied with a copy of the
purchase receipt. Doing so will qualify you for the Limited Lifetime Warranty!

6