FASS Diesel Fuel Systems - Diesel Fuel Pumps and Systems
FASS Diesel Fuel Systems - Diesel Fuel Pumps and SystemsDiesel Fuel System Warranty Registration & Policies - FASS Diesel Fuel Systems | In God We Trust
Installation Guide for FASS models including: ND-TSP-D11-140F-110G Titanium Signature Series Plus, ND-TSP-D11-140F-110G, Titanium Signature Series Plus, Signature Series Plus, Series Plus, Plus
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DocumentDocumentTITANIUM SIGNATURE SERIES PLUS INSTALLATION MANUAL ALL 1/2" FUEL PORTS APPLICATION: ND-TSP-D11-140F-110G (110GPH @ 70PSI) 3.0L EcoDiesel Ram 1500 EcoDiesel 2014-2018 & 2019 CLASSIC LIFETIME WARRANTY AVAILABLE FASS DIESEL FUEL SYSTEMS® / ENGINEERED EXCELLENCE www.fassride.com (866) 769.3747 Thank you for choosing FASS, from Diesel Performance Products, Inc. FASS specializes in building extremely high-quality fuel products. We have earned an unsurpassed reputation for excellence in our industry by using only the highest-quality American-made components. In order to support our American workers and our American economy, more than 98+ percent of our products are manufactured completely in the United States. Of course, that dedication to excellence comes at a price, but it is important to remember that price does not dictate quality-quality dictates price! We will never compromise by using cheaper, foreign-made components, like so many of our competitors do. Customer satisfaction is our top priority and we strive always to provide outstanding customer service. Our Research and Development department, in conjunction with our Dealer Support Department, continually searches for ways to improve quality, expand our product line, and provide superb support. Our exclusive ViP Network ensures that customers receive the proper products and support at the local level. The extended lifetime warranty is only available on products purchased from the network. There is no warranty on products not purchased outside the network. IMPORTANT: In order to qualify for the lifetime extended warranty, your product registration form and proof of purchase from an authorized dealer must be submitted to FASS Fuel Systems within 30 days of purchase. Failure to comply will void the warranty. We have the right to deny any warranty believed to be false, altered or purchased through an unauthorized or terminated dealer. A current list of authorized dealers can be found on our website, FASSRide.com. The complete conditions of the Limitation of Warranty can be found in the back of this manual, and FASSRide.com. For more information, contact Technical Support: Diesel P16e2rf3o4rmSatantceeHPwroydOuc. ts, Inc. Mart6h3a6s-v4il3le3, -M5O41603357 www.fassride.com (866) 769.3747 WARNING! This product has NO WARRANTY unless: 1. It has been purchased from an Authorized or ViP FASS Dealer. If in doubt, check www.FASSRide.com. 2. It is registered within thirty (30) days of purchase. Other conditions may apply. Please see full warranty information. NOTE: Warranty is void if product was purchased below FASS website advertised pricing. ATTENTION! Before you begin installation Register for your Warranty ONLINE at https://www.fassride.com/register-a-warranty/ No online access, call our TECH Support at 1-866-769-3747 www.fassride.com (866) 769.3747 FOLLOW THESE STEPS TO ENSURE A SIMPLE, CORRECT INSTALLATION OF YOUR NEW TITANIUM FUEL SYSTEM ATTENTION: Be sure to identify the proper FASS System and fuel line configuration. For help, our product finder can be found at www.FASSride.com. Follow the instructions to see fuel line detail. 1 Pay close attention to ALL WARNINGS 2 Read all instructions before installation of this product. starting 3 Inventory the package components. place of purchase immediately of Notify the any parts missing or damaged. 4 The installation recommendations contained within are guidelines. Use good judgment and take into consideration your vehicle's accessories. 5 For best results in accuracy and efficiency (due to training, communication, and our relationship with our dealer network), we recommend a VIP FASS dealer for the installation. They are prepared to install the FASS fuel pumps with the most efficiency. If a situation or problem arises during the installation, the dealer is prepared to handle it. Diesel Performance Products, Inc. is not responsible for any installation mistakes. 6 If you have any questions or concerns that cannot be addressed with your dealer, email or call FASS. If any installation procedure is uncertain, contact FASS technical support. Call customer service at 636-433-5410, or send us an e-mail: techsupport@FASSride.com with the following information: Your name, address and daytime phone number Model (ND-TSP-D11-140F-110G) Last 6 digits of vehicles' VIN Date of purchase Nature of Your Concern Serial number Serial # > www.fassride.com (866) 769.3747 INSTALLATION MANUAL ND-TSP-D11-140F-110G (Installation Videos are available at www.fassride.com) Recommended Application ND-TSP-D11-140F-110G: Ram 1500 EcoDiesel 2014-2018 & 2019 CLASSIC with stock to 700 HP. 1. Read all instructions before starting installation of this product! 2. Installing the improper FASS Pump can cause severe engine damage. 3. Secure vehicle from ROLLING! 4. Cab and Chassis may require modifications 5. Consult vehicle's manufacturers' instructions concerning the electrical system before attempting any electrical connections. 6. Flush and clean all brass fittings and fuel line from debris. 7. Keep debris from entering the internals of the system during installation. Getting debris in the water separator nipple can lock up the motor. If the motor does lock up from debris call FASS for technical assistance. 8. Wear safety glasses when operating power tools such as drills and grinders or when using a punch or chisel. 9. Properly secure lines to prevent chaffing. BEFORE STARTING THE INSTALLATION PROCESS LUBRICATE THE BED BOLT WITH WD-40 TO HELP WITH INSTALLATION www.fassride.com (866) 769.3747 WARNING! Always be sure to fill the fuel tank to full after a new FASS installation. Failure to do so can result in excessive sound output, or priming issues! Rear View TITANIUM www.fassride.com (866) 769.3747 SIGNATURE SERIES PLUS 110 GPH 70-75 psi (Approximately) 3. 6. 1. Front View 2. PUMP GUIDE: 1. "E" To Engine 2. "R" Return to Tank 3. Serial Number 4. "T" Fuel Inlet 5. Electric Heater Ports 6. "G" Gauge Port 5. 4. INSTALLATION GUIDE: Step 1. Install Electrical Harness Step 2. Prep the FASS Step 3. Mount the FASS Step 4. Fuel Line Supply Step 5. Review Installation TITANIUM www.fassride.com (866) 769.3747 SIGNATURE SERIES PLUS 110 GPH 70 PSI (Approximately) Note: Going over 100 PSI WILL void warranty. NOTE: WARRANTY MAY BE VOID IF SILICONE BAND IS REMOVED FROM MOTOR!! The silicone band is in place to retain motor wires, preventing damage to the electric motor. CONTENTS www.fassride.com (866) 769.3747 NOTE: Owner's Manual available for download on our website, www.FASSride.com FL-1002-BK x17' FL-1058-BK x7' MP-TSP-9078-ND RELAY COVER 30 AMP FUSE THREE (3) 1,200°F HEAT SHIELD PBR-2002 WH-1006-3 PFB-2001C PFB-2002 PBR-2003 PACKMAOGUENCTOINNTGENTS www.fassride.com (866) 769.3747 OR-350VITON 0424860 PL-2058-BK TWO (2) PL-2003-BK AN-8-ORB-10-BK AN-10-ORB-10-BK PL-8-ORB-10-BK PL-10-ORB-10-BK 1/2" x 4-1/2" BOLT TUBE CLAMP 1/2" x 13 NUT PLB-1238 SELF TAPPING SCREW HEX BOLT 1/2" -13x 1 1/2" THREE (3) WA-1001D FOUR (4) 3/8" WASHERS 46116 ADD-A-CIRCUIT 46177 THREE (3) 1/2" TWO (2) RING TERMINAL WASHERS FOUR (4) HEX BOLT 3/8" -16x 1 1/2" THREE (3) HEX BOLT 1/4" -20xl FOUR (4) LOCKING NUT 3/8" 3/4" SHCS 3/8"-16x2" PACKMAOGUENCTOINNTGENTS www.fassride.com (866) 769.3747 RS-2002 RS-2002A RS-2001 RS-2001C SP-5501 SC-5501 TWO (2) OR-017 OR-030 NOTE: THESE SPARE BASE O-RINGS ARE INCLUDED WITH THE KIT IN THE EVENT OF A PINCHED O-RING DURING ASSEMBLY DIELECTRIC GREASE CABLE TIES WARNING: www.fassride.com (866) 769.3747 The supplied 1,200°F heat shielding must be installed where FASS fuel line routes above the exhaust system. Failure to install heat shielding can result in a possible fire hazard! NOTE: FASS Fuel System will be installed on the passengers side of this vehicle! Install heat shielding where fuel lines route above the exhaust system! www.fassride.com STEP 1: (866) 769.3747 INSTALL ELECTRICAL HARNESS The installation of the electrical harness is done first, allowing power to be applied to the pump for lubrication purposes later in the installation. NOTE: USE SUPPLIED DIELECTRIC GREASE SPARINGLY ON ALL ELECTRICAL CONNECTIONS! www.fassride.com STEP 1: (866) 769.3747 INSTALL ELECTRICAL HARNESS The installation of the electrical harness is done first, allowing power to be applied to the pump for lubrication purposes later in the installation. Install the Relay Cover onto the relay on the FASS harness. www.fassride.com STEP 1: (866) 769.3747 INSTALL ELECTRICAL HARNESS The installation of the electrical harness is done first, allowing power to be applied to the pump for lubrication purposes later in the installation. NOTE: BE SURE TO INSTALL THE SUPPLIED 30 AMP FUSE INTO THE FASS WIRING HARNESS!! www.fassride.com STEP 1: (866) 769.3747 INSTALL ELECTRICAL HARNESS The installation of the electrical harness should be completed first. This will allow power to be applied to the pump during installation. A. Using wire stripping tool, remove excess insulation off the add-a-fuse and the WH-1006-3. www.fassride.com STEP 1: (866) 769.3747 INSTALL ELECTRICAL HARNESS B. Place wire from ADD-A-CIRCUIT 46177 and WH-1006-3 into butt connector. Using crimping tool connect ADD-A-CIRCUIT 46177 and WH-1006-3 with butt connector. Install 46251 toADD-A-CIRCUIT 46116topslot(opening thatisnear the spade). www.fassride.com STEP 1: (866) 769.3747 INSTALL ELECTRICAL HARNESS C. Crimp the ring terminals to the red and green wires of the WH-1006-3Wire Harness. Attach red wire to the positive terminal of the battery and the green terminal to the negative terminal.The use of a corrosion preventative on electrical connections is recommended. www.fassride.com (866) 769.3747 STEP 1: INSTALL ELECTRICAL HARNESS D. Secure relay and fuse in an upright position, as shown, to prevent moisture from entering. Dielectric grease may be applied to prevent corrosion. Fuse RELAY www.fassride.com STEP 1: (866) 769.3747 INSTALL ELECTRICAL HARNESS E. Route ADD-A-CIRCUIT 46177 lead into the fuse panel in the engine compartment, it may be necessary to add a small hole in fuse panel to route wire harness. If adding a small hole, position in a good location that will prevent water intrusion. Install ADD-ACircuit in fuse position #F70 (FUEL PUMP MTR), this will allow the FASS to trigger on from the OEM pump circuit. www.fassride.com (866) 769.3747 STEP 1: INSTALL ELECTRICAL HARNESS F. Route WH-1006-3 wire harness along frame rail to mounting location of pump. Completion of this step will be addressed in the Mounting Step 3. NOTE: www.fassride.com (866) 769.3747 ATTENTION: While installing fittings into Titanium pump DO NOT Apply side pressure to draw tube of pump PROPER IMPROPER STEP 2: www.fassride.com (866) 769.3747 MOUNT FUEL SYSTEM NOTE: Before installing fittings make sure to inspect for burs or flare imperfections. When cutting fuel line make sure to blow out line to keep debris from moving forward.. A. InstallAN-8-ORB-10-BK into the "E" port and AN-10-ORB-10-BK intothe"T" port of the FASS, tighten accordingly. STEP 2: www.fassride.com (866) 769.3747 MOUNT FUEL SYSTEM B. For fitting purposes. Secure PBR-2001 to pump assembly lightly with (3) 1/4"-20x1 3/4 bolts and (3) WA-1001D. Assembly will be used in future steps for correct fitting of brackets. (Note: Bracket may-be flipped to accommodate your application.) T T STEP 2: www.fassride.com (866) 769.3747 MOUNT FUEL SYSTEM C. Mount PBR-2003/RS-2002A onto the PASSENGER SIDE frame rail using supplied 1/2" x 4-1/2" bolt, 1/2" Washer and PFB-2001C/RS-2001C. STEP 2: MOUNT FUEL SYSTEM www.fassride.com (866) 769.3747 D. Secure PFB-2002 and RS-2001 to PBR-2003 with supplied 1/2" x 1-1/2" bolt and (2) 1/2" washers. STEP 2: MOUNT FUEL SYSTEM www.fassride.com (866) 769.3747 E. Position the PBR-2001 to the PFB-2002 pump assembly at the mounting location and check for fit. Once location is established mark location for mounting in next step. STEP 2: MOUNT FUEL SYSTEM www.fassride.com (866) 769.3747 F. Assemble the FASS pump bracket PBR-2001 using the RS-2002 spacer between PFB-2002 and PBR-2001 bracket with 4-3/8 bolts, nuts, and washers. Note: Torque bolts not flange nut. STEP 2: MOUNT FUEL SYSTEM www.fassride.com (866) 769.3747 G. Once secure use 3-1 1/2 bolts and 3-WA-1001D spacers to mount the pump to the bracket. STEP 2: MOUNT FUEL SYSTEM www.fassride.com (866) 769.3747 H. 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. STEP 2: www.fassride.com (866) 769.3747 MOUNT FUEL SYSTEM NOTE: If fuel pressure gauge is pulsating after FASS installation, use snubber valve (Cat Part # 7S-3795) I. Apply motor oil to gasket located on filters. Attach to system and hand tighten. Extreme Water Separator - Install XWS-3002 on side of pump with draw tube in the middle of the filter nipple. Particulate Filter Install PF-3001 on filter nipple without the draw tube. Make sure to insert O-Ring provided on nipple. Note: O-Ring must be put back on suction side of pump. Failure to do so can result in priming issues, cavitation or pressure losses. STEP 3: SUMP INSTALLATION www.fassride.com (866) 769.3747 A. Locate the lowest point of the fuel tank, which is typically below the factory fuel module. On some applications there is a dimple you can use for a center point reference and it has the flattest surface for sealing the sump. STEP 3: SUMP INSTALLATION www.fassride.com (866) 769.3747 B. Using the center point, drill a small hole to drain the remaining fuel. Recommend having a container large enough to retain the remain fuel. Allow fuel to drain completely. STEP 3: SUMP INSTALLATION www.fassride.com (866) 769.3747 C. Using a 3-3/4" hole saw drill the center point previously marked or notated. STEP 3: SUMP INSTALLATION www.fassride.com (866) 769.3747 D. Deburr hole and remove all shavings. STEP 3: SUMP INSTALLATION E. Install SC-5501 into fuel tank positioned as shown. www.fassride.com (866) 769.3747 NOTE: THIS SIDE FACES SP-5501 NOTE: THIS SIDE FACES THE INSIDE OF TANK STEP 3: SUMP INSTALLATION www.fassride.com (866) 769.3747 F. Using grease, install OR-350VITON into the groove of SP-5501. STEP 3: SUMP INSTALLATION www.fassride.com (866) 769.3747 G. Install the supplied 3/8-16x2" SHCS through 0424860 and hand tighten SP-5501 into place. NOTE: 0424860 MUST BE INSTALLED BEFORE TIGHTENING SP-5501 INTO PLACE STEP 3: SUMP INSTALLATION www.fassride.com (866) 769.3747 H. Rotate SP-5501 to your desired position and torque the 3/8-16x2" SHCS to 12 FT/ LBS . www.fassride.com (866) 769.3747 NOTE: RETURN PORT AND POCKET NOTE: SUPPLY PORT AND POCKET STEP 3: SUMP INSTALLATION www.fassride.com (866) 769.3747 I . Install PL-8-ORB-10-BK into the return port of SP-5501 and tighten accordingly. STEP 3: SUMP INSTALLATION www.fassride.com (866) 769.3747 J. Install PL-10-ORB-10-BK into the suction port of SP-5501 and tighten accordingly. STEP 4: INSTALL FUEL LINE Caution: DO NOT use sealant on AN fittings www.fassride.com (866) 769.3747 A. Install the fuel line heat shield on all 3 fuel lines that will be routed over the exhaust system. Be very sure the shielding is perfectly centered above the exhaust! STEP 4: INSTALL FUEL LINE www.fassride.com (866) 769.3747 B. Using grease, press the fuel return line to the return port fitting of SP-5501. Route the fuel line to the "R" port on the FASS, then install PL-2003-BK into FL-1002-BK using grease. Install PL-2003-BK onto the FASS return fitting and tighten accordingly. STEP 4: INSTALL FUEL LINE www.fassride.com (866) 769.3747 C. Using grease, press the suction line onto the PL-10-ORB-10-BK in the suction port of the sump. Route FL-1058-BK to the "T" port of the FASS and trim to length. Press PL-2058-BK into FL-1058-BK using grease, install onto AN-10-ORB-10-BK and tighten accordingly STEP 4: INSTALL FUEL LINE www.fassride.com (866) 769.3747 Caution: DO NOT use sealant on AN fittings D. Install the remaining FL-1002-BK onto PLB-1238, connect PLB-1238 to the OEM engine feed line above the fuel tank module. STEP 4: INSTALL FUEL LINE www.fassride.com (866) 769.3747 Caution: DO NOT use sealant on AN fittings E. Route FL-1002-BK over to the FASS, install PL-2003 onto the "E" port of the FASS. Measure and cut FL-1002-BK to length and install onto PL-2003 with oil. STEP 4: INSTALL FUEL LINE www.fassride.com (866) 769.3747 Caution: DO NOT use sealant on AN fittings F. Using the supplied tube clamp and self tapping screw, secure one of the fuel lines high above the exhaust system. Secure all fuel lines together tightly using supplied cable ties.FAILURE TO IMPROPERLY PERFORM THIS STEP CAN RESULT IN A FIRE HAZARD!!!! Note: Secure all fuel lines with cable ties. Cable ties are an economical way to prevent the possibility of problems occurring! STEP 4: INSTALL FUEL LINE www.fassride.com (866) 769.3747 G. We recommend putting approximately 5 gallons of fuel in the tank prior to filling the tank to check for fuel leaks. Prime the FASS system and check for leaks. Once you confirm no fuel leaks, the tank can be filled to capacity. STEP 5: REVIEW INSTALLATION www.fassride.com (866) 769.3747 Note: O-Ring must be put back on suction side of pump. Failure to do so can result in priming issues, cavitation, or pressure loses. 1. Blow out any open lines/cover any open ports 2. Bolts and fasteners properly tightened? 3. Electrical harness and fuel lines secured and properly tightened? Reconnect the battery. 4. Has the system been primed? a. Turn key to the ignition position, turning on the FASS pump for 15 sec.. b. Crank engine and allow to run for at least 1 minute. 5. Check for leaks. 6. Start the engine 7. Recheck all fluid and filter connections for leaks 8. This pump comes with a 1 Year Manufacturer's Warranty based on the date it has been manufactured. To receive your extended Lifetime Warranty, you have 30 days from date of purchase to send the completed warranty information www.fassride.com (866) 769.3747 LIMITATION OF LIFETIME WARRANTY Disclaimer: To help insure you receive the proper system and customer support at the local level, FASS has a VIP and Authorized Dealer network representing FASS products. This is one reason you must purchase through a dealer to comply with our warranty policies. If you do not, there is no warranty! We recommend you go to www.FASSride.com, click "Find a Dealer", put in their ZIP code, select the type of dealer, and see if the company you purchased from is listed. If they are not, put their phone number in the field below the ZIP code field to see if they are listed. Below these two fields is a list of "Terminated/Unauthorized" dealers. You may want to review this list. If the company is not listed or is on the "Terminated/Unauthorized" list, we suggest you return the product immediately to that dealer and call FASS. We'll recom-mend you to the nearest dealer. Diesel Performance Products, Inc. (hereafter "SELLER") gives Limited Warranty as to description, quality, merchantabil-ity, fitness for any product's purpose, productiveness, or any other matter of SELLER'S product sold herewith. The SELL-ER shall be in no way responsible for the product's open use and service and the BUYER hereby waives all rights other than those expressly written herein. This Warranty shall not be extended or varied except by a written instrument signed by SELLER and BUYER. When MANUFACTURER receives the "ORIGINAL" PRODUCT REGISTRATION form with a copy of the "BILL OF SALE/SALES RECEIPT" within 30 days of the sale, then the following applies! The Warranty will then and only then be validated to that of which typically accompanies your unit for your specific application from the date of sale or for recommended service life and limited solely to the original purchaser and/or vehicle and parts contained within the product's kit. This warranty does not cover normal wear on consumable items such as but not limited to filters, fuel line, wire harness & etc. The warranty does not cover seized gears due to lack of filtration. Warranty is voided if used with other than diesel fuel. Returned items will arrive prepaid to the place of purchase. Diesel Performance Products, Inc. will repair, without cost, any product found to be defective during the warranty period; parts only, or at its option, will replace such products in exchange for the product. Repair or replacements are warranted for the remainder of the original warranty peri-od. All Warranty claims are subject to approval by Diesel Performance Products, Inc. A Return Material Authorization (RMA) number must be obtained before any product is to be returned to Diesel Performance Products, Inc. for warranty consideration, repair or product return. Requests for product returns must be offset by an equal value order. Return parts must be completed and in resalable condition. No returns after 30 days. The following information is required to obtain a RMA number before returning product: Your Name, Address, and Phone Number's Model and Serial Number (Not Motor Number) Example: Model HD Series, Serial: 00125966 VIN Number of Vehicle Date of Purchase Nature of Problem RMA and Product Serial Number must be on all paperwork and correspondence. Failure to obtain the required information or paperwork will result in $25.00/item penalty and delay or denial of any warranty claim. Under no circumstances shall the SELLER and/or MANUFACTURER be liable for any labor charged or travel time in-curred in diagnosis for defects, removal, or reinstallation of this product, or any other contingent expenses. Under no circumstances shall the SELLER and/or MANUFACTURER be liable for any damage or expenses insured by reason of the use or sale of any such equipment. This warranty does not apply to products which Diesel Performance Prod-ucts, Inc. has determined to have been misused or abused, improperly maintained by the user, or where the malfunction or defect can be attributed to the use of non-genuine Diesel Performance Products, Inc. parts. IN THE EVENT THAT THE BUYER DOES NOT AGREE WITH THIS AGREEMENT: THE BUYER MAY PROMPLY RETURN THIS PRODUCT, IN A NEW AND UNUSED CONDITION, WITH A DATED PROOF OF PURCHASE, TO THE PLACE OF PURCHASE WITHIN THIRTY (30) DAYS FROM DATE OF PURCHASE FOR A FULL REFUND LESS SHIPPING. THE INSTALLATION OF THIS PRODUCT INDICATES THAT THE BUYER HAS READ AND UNDER-STANDS THIS AGREEMENT AND ACCEPTS ITS TERMS AND CONDITIONS. ®FASS Diesel Fuel Systems is a Registered Trademark of Diesel Performance Products, Inc. © Copyright 2016, Diesel Performance Products, Inc.