INSTALLATION MANUAL APPLICATION: FA D09 095G (95gph @ 15psi) Cummins 5.
Dear Valued Customer, “Made in the USA” is not just a slogan at FASS; it’s what we live by! FASS is not only assembled in the USA but 98%+ of the FASS product is manufactured in the USA, helping to employ Americans and strengthen America. At FASS, we scrutinize our suppliers and demand the highest quality American-made components. However, this does come at a price, which is one of the main reasons FASS products are more expensive than the competition.
¡WARNINGs! Read all instructions before starting installation of this product! Installing the improper FASS Pump can cause severe engine damage. FASS FA D09 095G Recommended Application Cummins (12 Valve) 1994-1998 with stock - moderate horsepower modifications pumping to the factory mechanical lift pump Note: Due to the increase of fuel flow you may encounter a problem with the stock fuel module. Adding a FASS suction tube kit will solve that issue.
INSTALLATION MANUAL Follow these steps to ensure a simple installation of your new FASS ADJUSTABLE FUEL PUMP 1. Read the installation manual completely before attempting installation. The installation of this product indicates that the buyer has read and understands the limitations of the FASS manufacturers warranty agreement and accepts the responsibility of its terms and conditions. 2. Inventory the package components. Notify the place of purchase immediately of any parts missing or damaged. 3.
Adjustable Fuel Pump Series 95 GPH 15 PSI (Approximately) A fuel pressure gauge is highly recommended to identify fuel filter life and to prevent engine damage! Adjustment Lock Nut Set screw Boost Compensation Port “E” To Engine ‘T’ Fuel Inlet Port Fuel Pressure Port Installation Step 1: Step 2: Step 3: Step 4: Step 5: Install Electrical Harness Mount Fuel System Install Fuel Line Check/Set Pressure Check Installation
Contents THB-1001 FF-3248 BHB-1001 MP-9006 FPB-2005 FL-1002 x14’ WH-1001
Mounting Package Contents RS-1002 HC-1001 46044 10-300 46260 PL-1005 Ring Terminal 10-299 QD-1001 *Cable Ties* 1/4” washer 1/4” Nut RS-2001 4 1/4 - 20x1.75” 2 1/4 - 20x1.
The installation of the electrical harness is done first, allowing power to be applied to the pump for lubrication purposes later in the installation. A. Using wire stripping tool remove excess insulation off the add-a-fuse and the WH-1001. B. Place connector from 46044 and to the red wire of the WH-1001. Using crimping tool connect 46044 and WH-1001 with butt connector. Install 46260 to 46044 bottom slot (opening that is near the spade).
E. The red lead of the wire harness will travel thru the rubber grommet or into the fuse panel in the engine compartment. The use of corrosion preventative spray is recommended. F. Locate fuse box under hood and select ignition hot fuse. Remove fuse and put Add-A-Fuse in place. Install fuse previously removed. The use of a corrosion preventative on electrical connections is recommended. G. Route wire harness along frame to the mounting location of the FASS pump.
A. Locate bed bolt and remove the bolt. Position RS-2001 between FPB-2005 and truck bed. B. Secure THB-1001 to bolt on bracket with the RS 1002 and the (2)– 1/4-20x1 bolts, 1/4 washers, and 1/4 nuts. With the (4)-1/4-20x1.75” bolts thread the BHB-1001 to the THB-1001. Note: Use of Anti-seize compound is highly recommended. C. Using thread tape, install the 2 10-300 into the “T” & “E” ports. Torque to 40 ft./lbs.
D. Slid the FASS pump into mounting brackets with the weep hole facing down. Torque (4) bolts to 110 inch pounds. VERY IMPORTANT: REMEMBERING THE POSITION OF THE “T” PORT, THERE IS A SMALL WEEP HOLE IN THE BASE DIRECTLY NEXT TO THE ELECTRIC MOTOR, THIS HOLE MUST AIM DIRECTLY TO THE GROUND!! IMPROPER INSTALLATION OF THE PUMP CAN CAUSE PREMATURE WEAR AND VOID MANUFACTURES WARRANTY.
Do Not use sealant on AN (male flare) fittings. Only use sealant on threads installed into pump assembly. A. Using a 3/8” hose clamp install the QD-1001 into the fuel line. Oil orings inside Quick Disconnect. B. Disconnect factory suction line clip by pressing in on the two tabs located on either side in the connection fitting. Once removed, clean the suction tube and connect the QD-1001 addressed in the previous step. Loop fuel line over frame. This will be addressed in step Installing Fuel Line.
The preset pressure is approximately 15 psi. Follow these steps to check or reset the fuel pressure. The port with 1/8” Allen plug marked with the letter “P” is your fuel pressure port. Exceeding factory fuel pressure may result in severe engine damage. Consult with engine manufacture before adjusting pressure! With the pump running – Loosen the lock nut Turn the adjustment screw clock wise to increase pressure and counter clock wise to decrease pressure.
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.
