INSTALLATION MANUAL APPLICATION: T 200G (200gph @ 45psi) CLASS 1-CLASS 8 *Requires a Fuel Line Kit*
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! WARNING: Do not tie FASS Return in with engine return. Back pressure can cause damage to engine. Read all instructions before starting installation of this product! Installing the improper FASS Pump can cause severe engine damage. This unit was not designed to be used on Unit Injected Mechanical Engines. Refer to the FASS kits with UIME in the model number. FASS Recommended Application T 200G Class 1– Class 8, Agriculture, Industrial, Recreational, Hwy and off-road.
INSTALLATION MANUAL Follow these steps to ensure a simple installation of your new FASS TITANIUM FUEL SYSTEM 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.
Titanium Duty Series 200 GPH 45 PSI (Approximately) A fuel pressure gauge is highly recommended to identify fuel filter life and to prevent engine damage! “H” Coolant Heater “E” To Engine ‘T’ Fuel Inlet ‘R’ Fuel Return to Tank 2nd Electric Heater Port Electric Heater Port ‘G’ Fuel Pressure Serial Number Location Installation Step 1: Step 2: Step 3: Step 4: Step 5: Install Electrical Harness Prepare Suction and Return Lines Mount Fuel System Install Fuel Line Check Installation
Contents MP-9050 BR-2001 WH-1005 *WE-1001*
Mounting Package Contents RS-2684 10-273 Ring Terminal 4 3/8-16”x 1 1/2” Hex Bolt RS-1001 Spade Terminal 4 Locking Nut 3/8” Mounting template 3 Hex Bolt 1/4-20 13/4" 3 WA-1001D
The installation of the electrical harness is done first, allowing power to be applied to the pump for lubrication purposes. A. Select best location in firewall for passage of wiring harness from cab to engine compartment. B. Find or drill a 7/8” hole in firewall. Install RS-2684 grommet for ease of installation and protection of wire harness. C. Connect WE-1001 wire extension to the WH-1005. D.
Some of the photo’s are of a different application, procedures are the same. A. Remove primary fuel and/or water separator. If primary filter is part of the fuel pump, ignore this step. Note: Use thread tape on “ALL” male pipe threads, do not use on male flared fittings. B. Skip this step if primary filter is part of the engine’s fuel pump. If 90° fitting is needed use OEM fitting (as seen in this photo) B1.
Some of the photo’s are of a different application, procedures are the same. C. Attach BR-2001 to back of system using the spacers and 1/4” bolts. Use the two bottom bolts and the very top one bolt opening. D. Position system where it will be mounted. Mark the (4) mounting points (using the template located on the contents page). Prior holes may be used. Drill these marked locations with a 13/32 bit. E. Connect factory plug into the FASS harness. Turn key to “on”.
For optimal engine performance gains, the return line should return to its own port. A. Fuel lines, excluding nylon type fuel lines, in excess of 6 years old should be replaced due to interior lining deterioration. This condition can cause many problems including but not limited to: fuel starvation, uneven fuel tank levels and etc. B. When routing the return line from the FASS Fuel System, you will need to first identify your current fuel system.
Caution: Do Not use sealant on AN fittings. Only use sealant on threads installed into pump assembly or joining fittings. Note: No extra ports? - Refer to the option located at the back of the manual. Return line from FASS with straight ends to cross member where the line will “T” off. From “T” to each fuel tank with 1-straight fitting & 1-90° fitting on each line. These lines must be the exact length on both sides. A.
C. Assemble the “T” using (1) 3/8 NPT ‘T’, (2) -8 ANx3/8 MPT & (1) -8 ANx3/8 MPT 90° as seen in the photo. Note: Hose clamps are not recommended for push lock fittings. They will hold up to 300psi! Use oil on fittings and inside fuel line when installing Push-Lok fittings D. Attach the line completed in Step 4b to the return port of the FASS labeled with an “R”. Route to the center of the nearest cross member aligned with the ports in the fuel tank being used for return fuel.
Caution: Do Not use sealant on AN fittings. Only use sealant on threads installed into pump assembly or joining fittings. Note: No extra ports? - Refer to the option located at the back of the manual. A. Locate a fuel return port into the fuel tank. Most KW’s have a 1/4”, Peterbilts have 3/8” or 1/2” extra pipe plug located by the fuel lines at the top of the fuel tank. Other models may have an extra port some where at the top of the fuel tank.
Note: Hose clamps are not recommended for push lock fittings. They will hold up to 300psi! Use oil on fittings and inside fuel line when installing Push-Lok fittings C. Attach the line completed in Step 4b to the return port of the FASS labeled with an “R”. Route to the port in the fuel tank being used for return fuel. Measure, mark & cut. D. In the same manner as previously covered, route and loosely connect the fuel lines discussed in this section to the appropriate points of connection. E.
A. Attach the fuel supply line from the fuel tank to the FASS using a 10-273L or one of the fitting from the filter housing removed in step 2. IF fuel supply line connects directly to engine-the primary fuel filter is not remote mounted-skip to step C (Usually, not always, on NTC/STC’s and N14’s). B. Attach the fuel supply line from the FASS to the engine pump using a 10- 273L or one of the fittings from the filter housing removed in step 2.
Caution: Do Not use sealant on AN fittings. Only use sealant on threads installed into pump assembly or joining fittings. Return line from FASS with straight ends to cross member where the line will “T” off. From “T” to each fuel tank with 2-straight fittings on 2 of the lines going to the Vent Line & 1-90° fitting on Return line connecting to the FASS These lines must be the exact length on both sides. A.
F. Attach the line completed in Step 4b to the return port of the FASS labeled with an “R”. Route to the center of the nearest cross member aligned with the ports in the fuel tank being used for return fuel. Measure & mark this line as it will connect to the 90° fitting of the “T” in this location. G. Cut the fuel line and assemble a –8 AN hydraulic fitting in the opposite end of the line connecting to the “R” port of the FASS. H.
N. Locate Fuel Tank Vent Line and remove vent and vent line from tank. Thread tape reducer on both ends and install reducer into tank. Once reducer has been secured install “T” onto reducer and secure. Thread tape bushings and install them on the “T” . NOTE: Not all configurations will be able to be assembled this way.Install the vent line on the top portion of the “T” and the FASS return line into the middle of the “T”. Repeat previous steps on other tank to install the Double Vent Line Return Kit.
A. Bolts and fasteners properly tightened? B. Electrical harness and fuel lines secured and properly tightened? C. Has the system been primed, refer to owners manual? D. Check for leaks. E. Start the engine F. Recheck all fluid and filter connections for leaks G. Product registration filled out and ready to be mailed or faxed. (Bung fitting) A. Most Preferred & Easiest 1. Drill and tap a 3/8”fpt in the thicker band of aluminum as seen. 2.
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. Fuel Filter –Install FWS-3003 on side of pump with draw tube in the middle of the filter nipple. Water Separator Filter –Install FS-1001 on water separator nipple without the draw tube. Make sure to insert O-Ring provided on nipple.
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.
