Fuel Pro® Installation Instructions

FH230 Series Filter / Separator / Warmer

A
Vent Cap and Assembly
B (part no. 3944440 S)
Includes Vent Cap and
C Vent Cap Seal
A. Collar (part no. 3944445 S)
B. Vent Cap Vent Cap and Assembly
C. O-Ring (part no. 3944440 S)
D
D. Body Housing (part no. 3944443 S)
O-Ring Set
E
(part no. 3945061 S)
Includes Vent Cap Seal
E. Holddown Spring (part no. 3944441 S)
and Cover Seal
F. Filter Element (see Table 1 for ordering
information)
F
G. O-Ring Pac (part no. 3944449 S)
H. Check Valve Service Kit
G (part no. 3944447 S)
I. Fuel Pro, Unheated (see page 6 for
ordering information)
I J. Drain Valve (part no. 3944453 S)
H
K. Fuel Pro, Heated (see page 6 for
Unheated ordering information)
J
OR

K
H CAUTION: These instructions are intended for use by
professional mechanics who are trained in the proper
Heated use of power and hand tools, using appropriate safety
precautions (including eye protection).
page 2

Service Kit Installation Installation of the Fuel Pro Service Kit

Step 1 - With the engine shut down and at ambient
This system is installed between the fuel tank and temperature, close the fuel shutoff valve (if
the fuel pump after the primary fuel filter adapter equipped) and place a suitable container under the
head is removed and a special diverter cap is fuel filters.
installed on the secondary filter head. Diverter caps
are sold separately and are not part of the Fuel Pro Step 2 - Remove the primary fuel filter element
service kit. The diverter caps available for use with assembly, sedimenter, and/or water separator. Drain
this kit are listed in Table 1. This system is designed the used element and dispose of it in an
to be the only fuel filter in the fuel system. environmentally responsible manner, according to
state and/or federal (EPA) recommendations. The
Table 1 - Diverter Cap Part Numbers fuel can be returned to the tank.
Required Required Required
Diverter Cap Step 3 - Remove the secondary filter, if applicable,
Filter Head Filter Head Filter Head
Part Number and do one of the following:
Stud Size Seal ID Seal OD
3945182 S 1"-14 2.475" 2.895" a. Replace the filter with a fuel diverter cap.
3945183 S 1"-14 3.225" 3.435"
3945184 S M6 x 1.5 2.475" 2.895" b. Remove the filter head and connect the fuel
3945185 S 3/4" x 16 2.475" 2.895" hoses together.
3945186 S 7/8" x 14 2.475" 2.895"
Step 4 - Mount the Fuel Pro in the desired location
3945187 S M18 x 1.5 2.475" 2.895" keeping the following points in mind:
3945188 S 13/16" x 12 3.225" 3.235"
a. Mounting the Fuel Pro directly on the
WARNING: When diesel fuel is circulated through engine is NOT RECOMMENDED.
an operating engine, it can become very hot. To
prevent personal injury: b. Mount vertically with the cover and element
• Scalding hazard! Do not allow heated liquid pointing up.
fuel to come in contact with eyes or
unprotected skin. Always allow the engine c. Make sure there is enough top and side
and fuel to cool to ambient temperature clearance for the cover to be conveniently
before replacing the fuel filter or performing removed for filter replacement.
service operations which could result in the
spillage of fuel from the fuel system. If this CAUTION: The Fuel Pro MUST be installed so
is not possible, protective clothing (face that the Filter Element is above the "FULL" level
shield, insulated hat, gloves, apron) must of the fuel tank.
be worn.
Step 5 - Route the fuel supply line from the fuel tank
• Heated diesel fuel can form combustible to the Fuel Pro inlet (Figure 1). Route a fuel line from
vapor mixtures in the area around the fuel the Fuel Pro outlet to the fuel pump inlet.
source. To eliminate the potential for fire,
keep open flames, sparks or other potential Step 6 - To minimize restrictions, observe the
ignition sources away from the work area, following guidelines when plumbing the system.
and do not smoke during filter replacement
or service operations which could result in a. Keep the fuel line routing as smooth as
the escape of diesel fuel or fuel vapors. possible with no low hanging loops which can
• Always perform engine or vehicle fuel trap water.
system maintenance in a well ventilated
area that is kept free of bystanders. b. Use 90° elbows only when necessary.
 page 3

c. If the fuel hoses are made up to length on the Engine Coolant Heat
job, be sure that the inner liner of the fuel hose
is not cut by the fitting, creating potential check To use engine coolant as the Fuel Pro heating fluid,
valve effects. Also make sure hoses are clean connect a hose (Braided #6 or #8 hose) from the
and free of debris before installing. high pressure side of the engine coolant system to
the Fuel Pro Heater Base (see Figure 1). Either
heater port will work as an inlet. Route another hose
CAUTION: To avoid damaging the aluminum fuel
from the Heater Base to a low pressure port in the
processor body, do not overtighten fuel lines or
coolant system. DO NOT route into the cab heater
fuel line fittings.
system.

Optional Electric Preheater

The Electric Preheater can be used with heated
Fuel Return Fuel Pro Fuel Supply to
Through Heater Engine Fuel systems such as the ones described above or with
Transfer Pump Pump unheated systems. To install, follow the wiring
diagram in Figure 3.

Note: When wiring the Electric Preheater, use a

fuse NOT a circuit breaker.
Optional Heat
With Coolant
Key
Controlled
Circuit
Fuel
Pro
Fuel Tank 25 A
Fuse* B
Battery

Figure 1 - Fuel Pro Connections *24 V heaters use 15 A fuse

Without Relay (supplied in wire harness)
Fuel Heating Options
25 A
Note: The Engine Return Fuel Heat and Engine Fuse* Fuel
Coolant Heat options apply ONLY to the heater Pro
30/51 87
base shown in Figure 2. If the bottom plate is flat Battery
Key B
Controlled
with 1/2" NPT ports, only the Electric Preheater Circuit
86 85
can be used.
Relay

Engine Return Fuel Heat With Relay

Use a relay if the available keyed circuit *24 V heaters use 15 A fuse
will not handle a minimum of 25 A. (supplied in wire harness)
Electronic unit injected engines can use return fuel
as the fluid heat for the Fuel Pro. Route the return Figure 3 - Heater Wiring Options
fuel line from the engine into the Heater Base of the
Fuel Pro (see Figure 2). Either heater port will work Filter Change Procedure
as an inlet. Connect a second fuel return line from
the Heater Base to the fuel tank return port. Step 1 - Drain the fuel level to below the collar.

Step 2 - Check to make sure the drain valve at the

base of the Fuel Pro is closed.

Step 3 - Using the Collar/Vent Cap Wrench (part

Heater Base number 3944460 S), remove the clear cover from
Fuel or Engine Coolant the fuel processor by removing the collar. Discard
Connection Ports
the o-ring from the base of the cover. (A new o-ring
Figure 2 - Heater Base seal is supplied with the new filter.) Remove the
page 4

filter element from the Fuel Pro by pulling upward Priming the System
and twisting slightly. Be sure the sealing grommet is
removed from the center stud. Step 1 - Check to make sure the drain valve at the
base of the Fuel Pro is closed.
COLLAR
FUEL PRO Step 2 - Remove the vent cap from the top of the
clear cover. Fill the Fuel Pro full of clean fuel.
Reinstall the vent cap and tighten by hand only.
VENT
CAP

Step 3 - Start the engine. When the lubrication

system reaches its normal operating pressure,
increase engine speed to high idle for one to two
minutes. After the air is purged, loosen the vent cap
Figure 4 - Collar/Vent Cap Wrench until the fuel level lowers to just above the collar.
Step 4 - With the new filter (see Table 2) sealing Tighten the vent cap by hand only.
grommet (supplied with the filter) inserted into the
base of the filter element, install the element on the Note: The clear filter cover will not fill completely
processor center stud. After checking to make sure during engine operation. It will gradually fill over
the new o-ring seal (supplied with the filter) at the time and the fuel level will rise as the filter
base of the cover is in place, install the cover, spring becomes clogged .
and collar. Hand tighten the collar until seated. Do
not use tools to tighten. Step 4 - Hand tighten the collar again while the
engine is running. To avoid damage, do not use
Table 2 - Replacement Filters tools to tighten the collar.
Filter Part Number Description
CAUTION: To avoid damaging the aluminum fuel
FS19761 Elemax™ Stratapore™ 2 micron
processor body, do not overtighten fuel lines or
FS19624 Elemax™ Stratapore™ 7 micron fuel line fittings.
FS19729 EleMax™ Cellulose 50 micron
FS19728 EleMax™ Stratapore™ 25 micron Emergency Temporary Filter
FS19727 EleMax™ Stratapore™ 10 micron Replacement
Step 5 - Remove the vent cap from the top of the
clear cover by turning the vent cap counterclockwise. Step 1 - Follow Steps 1 through 4 of the "Filter
Fill the clear cover with enough clean fuel to cover Change Procedure" on page 3.
the bottom half of the filter element. Make sure the
new o-ring (supplied with the filter) is installed on the Step 2 - If there is a filter grommet on the filter stud,
vent cap. Reinstall the vent cap and tighten by remove it.
hand only.
Step 3 - Install an engine spin-on filter (partn number
Step 6 - Start the engine.When the lubrication FF105, for example) on the threaded stud.
system reaches its normal operating pressure,
increase engine RPM for one minute. Step 4 - Install the cover, spring, seal and collar over
the filter for later reuse and to guard against loss.
Note: The clear filter cover will not fill completely
during engine operation. It will gradually fill over Step 5 - Start the engine. Raise the RPM for one
time as the filter becomes clogged. The filter minute to purge the air from the system.
element does not need to be changed until the
fuel level has risen to the top of the filter
element.
 page 5

Draining Contaminants Suggested Preventive

Maintenance
Step 1 - Turn off the engine and open the filter vent.
Weekly - Drain water.
Step 2 - Place a cup under the drain valve at the
base of the Fuel Pro and open the drain valve. Every Filter Change - Change o-rings and grommet
(included with new filter).
Step 3 - Water will flow into the cup. When fuel
begins to flow out of the drain, close the drain valve. Every 12 Months - Check all electrical connections
(Drain the minimum amount of fuel possible.) for corrosion. Check all fuel fittings for leaks.

Step 4 - Close the filter vent. Extreme winter or salt corrosion environments may
require lubrication of the top collar threads with
Step 5 - Start the engine. Raise the RPM for one
Loctite® 76747 antiseize every 180 days.
minute to purge the air from the system.

Ordering Information
Housing Part
Filter Element Pre-Heater 1 Pre-Heater 2 Fluid Heat WIF Fuel Flow
Number
FH23027 FS19624 12 VDC 120 VAC Yes N/A In Right / Out Left
FH23028 FS19624 24 VDC 120 VAC Yes N/A In Right / Out Left
FH23029 FS19624 N/A N/A N/A N/A In Right / Out Left
FH23030 FS19729 N/A N/A N/A N/A In Right / Out Left
FH23031 FS19624 12 VDC N/A N/A N/A In Right / Out Left
FH23032 FS19624 24 VDC N/A N/A N/A In Right / Out Left
FH23038 FS19624 N/A N/A Yes N/A In Right / Out Left
FH23039 FS19624 N/A N/A Yes Yes In Right / Out Left
FH23040 FS19624 12 VDC N/A Yes N/A In Right / Out Left
FH23041 FS19624 12 VDC N/A Yes Yes In Right / Out Left
FH23042 FS19624 24 VDC N/A Yes N/A In Right / Out Left
FH23045 FS19624 120 VAC N/A Yes N/A In Right / Out Left
FH23049 FS19624 12 VDC N/A N/A Yes In Right / Out Left
FH23050 FS19624 24 VDC N/A N/A Yes In Right / Out Left
FH23054 FS19624 12 VDC 120 VAC N/A N/A In Right / Out Left

3945145 S Heater Wire Harness, Metri Pack Items Not Shown, 24 V:

3945123 S Heater Wire Harness, Weather Pack 3945136 S Fuel Heater Assembly
Upgrade Kits: Items Not Shown, 120 V:
3944456 S 12 V-250 W Preheater Upgrade 3945121 S Fuel Heater Assembly
3945193 S 24 V-250 W Preheater Upgrade 3945126 S Heater Cord
Items Not Shown, 12 V:
Contact Fleetguard Customer Support for proper part
3944450 S Fuel Heater Assembly
number information.
3945124 S Harness Kit, Weather Pack
3944455 S Harness Kit, Metri-Pack
page 6

Dimensions
Front Right Side Back

3.28 3.90 Service Height 7.30

(83.3) (99.1) 3.5 (88.9) (185.2)

16.00
(406.4)

1/2-14 1/2-14 .97

NPTF NPTF (24.6)
Fuel Fuel
Outlet Inlet
FUEL
IN
∅.43
(11.0)
(2 places)
5.10
(129.5)

5.91 3.46
(150.0) (88.00)
Bottom

6.58
(167.1)

.50 (12.7) All dimensions are in inches (millimeters)

Fleetguard Fuel Pro® 230 Series Specifications FH230 Series Restriction vs Flow
Height Overall 16.13" (409.7 mm) Flow (L/hr)
Depth Overall 7.25" (184.15 mm) 150 250 350 450 550 650 750
4.0
Width, max 6.89" (175 mm)

Differential Pressure (kPa)

10.0
Differential Pressure ("Hg)

3.5
Mount Bracket Centers 5.91" (150.11 mm)
3.0 12.0
Weight (Dry) 7.25-9.75 lbs (3.9 - 4.42 kg)
2.5 8.0
Fuel Connection (Inlet) 1/2"-14 NPTF
2.0
Fuel Connection (Outlet) 1/2"-14 NPTF 6.0
1.5
Fluid Heat Connection (Inlet) 1/2" NPTF 4.0
1.0
Fluid Heat Connection (Outlet) 1/2" NPTF 2.0
.5
Fuel Capacity (w/ filter) 64.2 oz (1.9 L) 0
0
Operation Fuel Flow Rate 150 gph (568 lph) 40
100 120 140 160 180 200 60 80
Recommended Application Heavy Duty Engines Flow (gal/hr)
FH230 Series With FS19624 Filter Element Per SAE J905
Water Trap Capacity 33.8 fl oz (1.0 L)
Filter Replacement FS19624* Filter Restriction vs Capacity
Filter Service Clearance Min. 3.5" (88.9 mm)
Electrical Heater 12 VDC, 250 W, 18 A ± 3 A 4 30
Restriction (kPa)
Restriction (psi)

24 VDC, 250 W, 11 A ± 2 A 25
3
20
120 VAC, 75 W, .65 A ± .1 A
2 15
* Other filter options at different Micron Ratings are available. 10
Specifications subject to change without notice. 1
5
0 0
40 50 0 60 10 20 30 70 80 90
Capacity (g)
FS19624 Filter Element Per SAE J905

LT32582 - Rev 1 For more information, contact Customer Assistance

©2004 Fleetguard Inc. at 1-800-22-FILTER (1-800-223-4583), fax 1-800-999-8664,
Printed in the U.S.A. or visit us at www.fleetguard.com