®

Te c h n o l o g y, L L C
TABLE OF CONTENTS
How it Works. . . . . . . . . . . . . . . . . 1
“SEEING IS BELIEVING”® . . . . . . . . . . . 2
• Important Safety Precautions . . . . . . . . . 3
Fuel Pro 382 Dimensions . . . . . . . . . . . . 4
Fluid Heater Installation. . . . . . . . . . . . . 7
12 VDC and 24 VDC Electric Pre-heater Installation. 8
Water in Fuel Sensor (WIF) Installation . . . . . . . 9
Preventive Maintenance. . . . . . . . . . . . 10
Filter Change Procedure . . . . . . . . . . . . 11
Visual Diagnostics. . . . . . . . . . . . . . 12
Diagnostic Procedures. . . . . . . . . . . . 14
Check Valve Diagnostics. . . . . . . . . . . . 17
Service Parts. . . . . . . . . . . . . . . . 18
Warranty and Customer Service . . . . . . . . . 21

FOR UPDATED INFORMATION, VISIT WWW.DAVCO.COM

FUEL PRO 382

®

TECHNICAL MANUAL
2012 ©DAVCO Technology,  LLC.
Updated 09/05/2012
 FUEL PRO® 382
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TECHNICAL MANUAL

How it Works
• Fuel from the tank enters the Fuel Processor body (suction side of the fuel system).
• Large contaminants and “free” water are separated from the fuel and remain in the body.
• Fuel rises into the clear cover.
• Contaminants and emulsified water are captured by the filter media.
• Fuel level rises to maintain a fuel path through the clean filter media with low restriction.
• Clean, water-free fuel exits the Fuel Processor and flows to the engine fuel injection system.
Fuel System Diagram

Figure 1

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“SEEING IS BELIEVING”®
• See when NOT to change the fuel filter.
• See the condition of the fuel. Seeing what collects on the filter media or what’s happening inside the clear cover
can help diagnose many fuel and mechanical conditions.
• “Filter on Top” configuration. Water and debris removed from the fuel falls to the lower chamber and stays away
from the filter media resulting in longer filter life.
• Built in protection when priming the fuel filter. Unfiltered fuel is kept on the “dirty” side of the filter media during
priming ensuring only clean fuel reaches the engine.
• Patented media. The “Best in Class” StrataPore™ media removes 98% of free and emulsified water over the life
of the filter. This far exceeds the performance of cellulose media.

When new, the fuel level in the filter will be very Fuel level increases in clear cover. As contaminants
low with minimal restriction. As the filter is used, collect on the filter, the fuel rises to a non-contaminat-
contaminants collect on the filter from the bottom up. ed section of the filter, providing optimal filtration while
Fuel rises on the filter indicating remaining filter life. maintaining lowest restriction.

Fuel level at filter wrap level. Even though the fuel The filter element is now completely covered by
level is now more than half of the filter element, the fuel. At this point, all of the media’s surface area is
fuel is still flowing through clean media at minimal utilized. Restriction is increasing and the filter element
restriction levels. The filter still has significant life should be changed at the next scheduled mainte-
remaining. nance interval.

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• Important Safety Precautions

EE General Safety Precautions
• Read all instructions before use to avoid injury
• To avoid serious injury or death, follow the safety information in this document
• Keep this manual
• Read all product safety labels
• Refer to appropriate regulations for environmental and workplace safety rules
EE To prevent personal injury
• Scalding hazard: When diesel fuel is circulated through an operating engine, it can become very hot. Do not
allow fuel to come in contact with eyes or unprotected skin. Allow the engine and fuel to cool to ambient tem-
perature before replacing the fuel filter or performing service operations which could result in spillage of fuel
from the fuel system. If this is not possible, protective equipment (face shield, insulated hat, gloves, and apron)
must be worn.
• Fire Prevention: Heated fuel can form combustible vapor mixtures in the area around the fuel source. To
eliminate the potential for fire, keep open flames, sparks or other potential ignition sources away from the work
area. Do not smoke during filter replacement or service operations.
• Inhalation Precaution: Always perform engine or vehicle fuel system maintenance in a well ventilated area
that is kept free of bystanders.
• The ignition key must be in the off position, unless otherwise directed. To avoid unintentional engine startup,
use a lockout key and/or signage to alert personnel that work is being performed.

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Fuel Pro 382 Dimensions

6.75 (171.5) MAX

SERVICE HEIGHT
1.5 (38.1)

3.28 (83.3) 3.9 (99.1)

16.00 (406.4) MAX

1/2" x 14
NPTF
FUEL INLET

1/2" x 14 NPTF FUEL

FUEL OUTLET Ø .43 (11.0)
IN

(2 PLACES)

5.91 (150.0) 3.46 (88.0)

FRONT RIGHT SIDE

6.58 (167.1)

.50 (12.7)

BOTTOM
All dimensions are in inches (millimeters)

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Installation Instructions
Installation Location Fuel Line Routing
The Fuel Pro must be installed between the fuel tank and To minimize fuel system restriction, observe the follow-
the fuel transfer pump. In some cases, the Fuel Pro can be ing guidelines when plumbing the fuel system:
used as the only fuel filter in the system. This is generally • Keep the fuel line routing as smooth as possible with no
dependent on the engine model year. Consult the engine low-hanging loops which can trap water.
manufacturer for their recommendation. If the Fuel Pro can
• Use 90° elbows only when necessary.
be used as a single filter, DAVCO offers a diverter cap to
replace the secondary filter. (See diverter cap installation • If the fuel hoses are cut to length on the job, be sure that
section) the inner liner of the fuel hose is not cut by the fitting,
which can cause check valve performance issues. Make
sure hoses are clean and free of debris before installing.
Mounting the Fuel Pro
• To avoid damaging the aluminum Fuel Pro body, do not
Mount the Fuel Pro keeping the following points in overtighten fuel lines or fuel line fittings.
mind:
Step 1: Route the fuel supply line from the pick up on the
• Do not install the Fuel Pro directly on the engine.
fuel tank to the Fuel Pro inlet (labeled “Fuel In”).
• Mount vertically with the cover and element pointing
Step 2: Route the fuel outlet line from the Fuel Pro outlet
up.
(labeled “Fuel Out”) to the inlet of the fuel pump.
• Make sure there is enough top and side clearance for
the cover to be conveniently removed for filter replace-
ment. Priming the Fuel System
• The Fuel Pro MUST be installed so that the Filter Ele- Step 1: Check to make sure the drain valve at the base of
ment is above the "FULL" level of the fuel tank. the Fuel Pro is closed.
EE The ignition key must be in the off position, unless Step 2: Remove the vent cap from the top of the clear
otherwise directed. To avoid unintentional engine cover. Fill the Fuel Pro full with clean fuel. Reinstall the vent
startup, use a lockout key and/or signage to alert cap and tighten by hand only.
personnel that work is being performed. Chock the
Step 3: Start the engine. When the lubrication system
wheels.
reaches its normal operating pressure, increase engine
Step 1: With the engine shut down and at ambient temper- RPM to high idle for one to two minutes. After the air is
ature, close the fuel shutoff valve (if equipped) and place a purged loosen the vent cap until the fuel level lowers to
suitable container under the fuel filters. just above the collar. Tighten the vent cap by hand only.
Step 2: Remove the primary fuel filter element assembly, Step 4: Hand tighten the collar again while the engine is
sedimenter, and/or water separator. Drain the used ele- running. To avoid damage, do not use tools to tighten the
ment and dispose of it in an environmentally responsible collar.
manner, according to state and/or federal (EPA) recom-
Note: The clear filter cover will not fill completely during
mendations.
engine operation. It will gradually fill over time and the fuel
level will rise as the filter becomes contaminated.

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Installation Instructions
Diverter Cap Installation Diverter Cap Required Required Required
If a single fuel filter system is approved by the engine Part Number Filter Head Filter Head Filter Head
manufacturer, the following steps are to be taken to install Stud Size Seal ID Seal OD
a diverter cap properly. 101480 1"-14 2.475" 2.895"
Step 1: Select the required secondary filter head diverter 101589 1"-14 3.225" 3.435"
cap from those listed in Table 1. The required diverter cap 101570 M16 x 1.5 2.475" 2.895"
is determined by the size of the spin-on filter stud and the
filter sealing surface diameter. 101466 3/4"-16 2.475" 2.895"
101492 7/8" x 14 2.475" 2.895"
Step 2: Drain and remove the secondary fuel filter element.
Step 3: Lightly lubricate the seal on the top of the diverter Table 1
cap with clean engine oil.
Step 4: Thread the adapter onto the secondary filter stud
and tighten by hand only.
Step 5: Install the “Do Not Remove” label on the diverter
cap.

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Fluid Heater Installation

The engine return fuel heat and engine coolant heat options apply ONLY to the fluid heater base shown in Figures 2 and
3. If the bottom plate is flat with 1/2" NPT ports, only the electric pre-heater can be used. Contact DAVCO Customer Ser-
vice to obtain the appropriate bottom plate.

Engine Coolant Heat Engine Return Fuel Heat

To use engine coolant as the Fuel Pro heating fluid, con- High flow and high temperature return fuel engines can
nect a hose (5/8" silicon heater hose) from the high pres- use the return fuel as the heating fluid for the Fuel Pro.
sure side of the engine coolant system to the Fuel Pro Route the return fuel line from the engine into the heater
heater base. Either heater port will work as an inlet. Route base of the Fuel Pro. Either heater port will work as an in-
another hose from the heater base to a low pressure port let. Connect a second fuel return line from the heater base
in the coolant system. DO NOT route into the cab heater to the fuel tank return port.(See Figure 3)
system. (See Figure 2)

return fuel
Fuel Pro Fuel Pro
transfer pump transfer pump

fuel tank fuel tank

coolant

inlet or outlet ports inlet or outlet ports

Figure 2 Figure 3

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12 VDC and 24 VDC Electric Pre-heater Installation

The Fuel Pro 382 12 VDC or 24 VDC electric pre-heater is
Pre-heater Wiring without Relay
installed in the processor base as shown in Figure 4.

FUEL PRO

Key Controlled Circuit

Fuse*

Switch Heater element

20 A
+
Battery

GND GND

*24 VDC pre-heaters require a 15 A fuse.

Figure 4
Figure 5
Step 1: Drain all the fuel from the Fuel Pro. The fuel can
be reused after the pre-heater is installed. If the fuel is not Pre-heater Wiring with Relay
reused, dispose of it in an environmentally safe way.
Step 2: Remove the pipe plug in the Fuel Pro base plate.
FUEL PRO
Step 3: Apply liquid thread sealant to the pre-heater
threads and install into the Fuel Pro base. Tighten to 15-30
ft-lbs.
Fuse*
Step 4: Connect the chassis harness and wire.
20 A Heater element
+
• For 12 VDC or 24 VDC without a relay, refer to Figure 5. Battery

• For 12 VDC or 24 VDC with a relay, refer to Key Controlled Circuit

Relay
Figure 6.
GND GND

• If the keyed circuit will not handle a minimum of 20 GND

amps, use a relay.

*12 VDC pre-heaters require a 20 AMP fuse. If the keyed circuit will not
• Provide proper (20 amp fuse) electrical protection for handle a minimum of 20 amps, use a relay.
source voltage supplied to the pre-heater.
Step 5: Remove the vent cap from the top of the clear Figure 6
cover. Pour fuel into the Fuel Pro to one inch below the
top of the filter element. Reinstall the vent cap and hand
tighten.
Step 6: 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 until the fuel level drops to
just above the collar. Tighten the vent cap by hand only.

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Water in Fuel Sensor (WIF) Installation

Step 1: Remove the ½"-20 WIF plug in the bottom of the Step 6: Install the WIF indicator light by pressing firmly
Fuel Pro. into the drilled hole.
Step 2: Install the WIF Probe (See Service Parts Page Step 7: Connect the black ground lead with a 3/8" diam-
for P/N) into the bottom of the Fuel Pro. Torque to 20-24 eter loop end on the WIF wiring harness to the ground
in-lbs. source near the Fuel Pro (if applicable).
Step 3: Install the WIF wiring harness (P/N 102600) on Step 8: Connect the green signal wire on WIF wiring
WIF Probe. The harness has the following connections: harness to green signal wire on WIF indicator light. Use
black ground lead with a 3/8" diameter ring terminal and additional green wire as needed.
a green WIF wire. Step 9: Locate 12 VDC or 24 VDC key controlled on
Step 4: Drill ½" hole in the instrument or control panel power source. Install a red wire from the power source to
where the WIF indicator light is to be located. the red wire on WIF indicator light. Add a 1 amp in-line
Step 5: Connect the black ground wire from the WIF fuse (not included).
indicator light to a ground source. Attach additional black Note: Use appropriate connectors to attach the wires. To
wire as needed. test the WIF indicator light, pour water into the body of
the Fuel Pro until it covers the WIF probe. The WIF indica-
tor light should illuminate.

WATER-IN-FUEL
(WIF) FUEL
WARNING LIGHT

WATER

PROBE

TO ANY KEYED
12 OR 24 VDC SOURCE RED GREEN

BLACK

CHASSIS
CHASSIS GROUND
GROUND

(Recommended fuse: 500ma for 12 VDC. Do not exceed 1 A.)

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Preventive Maintenance
• Weekly – Drain water
• Turn off the engine and open the vent cap.
• Place a suitable eight ounce, plastic or metal container under the drain valve at the base of the Fuel
Pro and open the valve.
• Water will flow into the container. When fuel begins to flow out the drain, close the drain valve. Drain
the least amount of fuel as possible.
• Hand-tighten the vent cap.
• Start the engine. Raise the RPM for one minute to purge the air from the system.
• Every filter change
• Change the cover and vent cap o-rings (included with the service filter kit).
• Every 12 months
• Check all electrical connections for corrosion. Check all fuel fittings for leaks.
• Seasonal Maintenance:
• Extreme winter or salt corrosion environments may require lubrication of the collar threads with anti-
seize lubricant every 180 days.

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Filter Change Procedure

For filter selection visit www.davco.com/parts.html (Parts Step 6: Reinstall the clear cover and collar. Hand tighten
And Cross Reference) for the correct filter for your applica- the collar.
tion or call DAVCO Customer Service at 800-328-2611. Step 7: Prime the unit by filling the clear cover with clean
Step 1: Remove the vent cap and open the drain valve to diesel fuel until it reaches the top of the filter.
drain the fuel below the collar level.
Step 8: Install the vent cap. Hand tighten only.
Step 2: Remove the collar (using the DAVCO collar
Step 9: Start the engine and run for one minute. Slowly
wrench) then remove the clear cover.
open the vent cap and allow the fuel to drop to about one
Step 3: Remove the filter, cover and vent cap seals. inch above the collar.
Dispose of the filter and the seals properly.
Step 10: Close the vent cap. Hand tighten only. It is
Step 4: Using a clean shop rag, clean the cover, the collar normal for the fuel level to vary after the initial start-up and
and threads on the Fuel Pro body. during engine operation. Filter performance is not affected.
Step 5: Install a new filter, cover seal and vent cap seal.

Service Wrench Information

• The DAVCO Fuel Pro vent cap and collar are
designed to be removed with a DAVCO wrench.
• Vent caps and/or collars damaged as a result of
not using the DAVCO wrench will not be covered
under warranty. Wrench is for removal ONLY.

Description P/N
Metal Collar/Vent Cap Wrench
Metal Collar/Vent Cap Wrench 380134

Composite Collar/Vent Cap Wrench 382002

Composite Collar/Vent Cap Wrench

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Visual Diagnostics
Fuel level is not at the top of the fuel Fuel level is at the top of the filter. Low
filter. power.
Î
ÎNormal - Do not change the filter. Î
ÎChange the filter at the first available
opportunity.

Fuel level is at the top of the filter and There is a power complaint and the fuel
appears to be full of wax. level is below the collar.
Î
ÎChange the filter - Run the engine for Î
ÎCheck for a missing grommet at the
a minimum of 25 minutes at idle. Do not lower end of the filter or missing/broken
run at full RPM. spring at top of filter.

Bubbles are seen flowing in with the Water is noticed in the cover.
fuel. Î
ÎDrain the water. If engine coolant is
Î
ÎCheck all fittings and lines from the visible, follow proper engine pressure
fuel tank to the fuel processor. Check testing procedures to determine root
lower and upper collar o-rings. cause.

Fuel drains back to the fuel tank when No engine coolant flow to the Fuel Pro
changing the fuel filter or draining sepa- heater.
rator. Î
ÎCheck for closed cutoff valves at
Î
ÎRemove the check valve assembly. the coolant lines to the fuel processor.
Clean or replace and retest. Check air Make sure the cab heater valve is open.
leaks in the fuel system.

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Visual Diagnostics
There are two kinds of bubbles that may be visible at the fuel pump inlet of a diesel fuel system. The bubbles can be
characterized as either air bubbles or vapor bubbles.

Air Bubbles (will affect engine performance) Vapor Bubbles (will not affect engine perfor-
Air bubbles are caused by any air leak on the vacuum (suc- mance)
tion) side of the fuel system from the fuel tank pick-up to, All diesel fuel has some level of entrained air caused by the
and including, the lift pump. (See Figure 7) natural splashing that occurs in the fuel tank during normal
If there is an air leak in the fuel system, air bubbles will vehicle or equipment operation. Vapor bubbles develop in
be present in the clear cover of the Fuel Pro. Follow test the Fuel Pro because the pressure inside the Fuel Pro is
procedures outlined in "Troubleshooting" for air leak diag- lower than the atmospheric pressure in the fuel tank. Vapor
nostics. bubbles can vary from champagne size up to ¼" in diam-
eter. They may increase in size or volume as engine RPM
If there are no bubbles present in the Fuel Pro cover and
the engine continues to run rough, lopes or has a loss increases. The lower pressure draws the entrained air/va-
of power, there may be an air leak between the Fuel Pro por out of the fuel and these bubbles will be visible as the
outlet port and lift pump inlet. This type of air bubble can fuel exits the Fuel Pro. (See Figure 8)
be seen if a sight tube is installed at the lift pump inlet. Air As the fuel enters the lift pump, it is pressurized and the
bubbles may also be visible in the fuel return (spill) hose bubbles are compressed back into the fuel. There will be
out of the fuel gallery. These leaks are easily eliminated by no bubbles on the fuel return side of the system. (See Fig-
checking and torquing the fuel fittings in the area of the ure 8). These vapor bubbles will not affect the performance
leak. of the engine.
If there are no air leak symptoms, but bubbles are pres- There is no diagnostic or repair procedure required for
ent in a sight tube at the fuel lift pump inlet, they are most vapor bubbles. Vapor bubbles do not cause performance
likely vapor bubbles. issues and will not be present after the lift pump.
Note: A quick procedure to determine if the air leak is
between the fuel tank and the Fuel Pro is to remove the
Fuel Pro inlet hose and route a new hose from the Fuel Pro
inlet into a container of fuel or the fuel tank fill cap opening.
Start the engine and check for bubbles.

ENGINE ENGINE
FUEL RETURN FUEL RETURN

LIFT PUMP LIFT PUMP

AIR
VAPOR
BUBBLES FUEL PRO FUEL PRO

BUBBLES
OR OTHER OR OTHER
PRIMARY PRIMARY
FILTER FILTER

Figure 7 Figure 8

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Diagnostic Procedures
Air Leaks 2. Plug the fuel outlet port. Do not
remove filter, cover/collar, vent cap,
Note: Every Fuel Pro is factory tested for leaks and is
drain valve and/or check valve. If the
identified with a traceable number prior to shipment. Most
Fuel Pro is equipped with a pre-heat-
field issues associated with leaks are related to loose
er, do not remove the pre-heater.
fittings. These leaks are easily eliminated by checking
and torquing the fuel fittings in the area of the leak. Some 3. Apply 15 PSI of air pressure at the
fittings may also require the application of liquid Teflon fuel inlet. Immerse the Fuel Pro in a
sealer. tank of water and look for air bub-
bles.
Note: All suction side fuel filters experience bubbles. It
is normal to see champagne size bubbles in the Fuel Pro 4. Correct the source of the air leak and
cover, at the Fuel Pro outlet or at the lift pump. retest.
B. Bubbles Not Visible: If there are symptoms of
IN ORDER TO RETURN A FUEL PRO FOR EVALU- sucking air (indicated by engine loping/rough
ATION, THE FOLLOWING PROCEDURES/TESTS running performance/power loss, etc.) and
MUST BE COMPLETED BEFORE REQUESTING A there are no bubbles in the clear cover, the air
DAVCO RGA (RETURN GOODS AUTHORIZATION) leak is either at the Fuel Pro outlet fitting, vent
NUMBER. cap o-ring, the lift pump inlet connection, or the
fuel hose/connections to the lift pump. Inspect
I. Air Leak: Air bubbles will be visible in the clear cover and tighten fittings as needed.
of the Fuel Pro if the leak originates between the fuel
II. Excessive Restriction: If the fuel level is at the top
tank up and the fuel filter. The following is a quick test
of the filter, replace the fuel filter. The Fuel Pro will
to isolate the air leak source.
not cause excess system restriction if the fuel level
A. Bubbles Visible: Remove the Fuel Pro inlet is below the top of the filter. The only exception is if
hose. the grommet is not installed in the bottom of the filter
i. Install a jumper hose from the Fuel Pro to element.
the fuel tank (through the fill cap) or to a III. Loss of Prime: When air is introduced into the fuel
container of fuel. system, (i.e. draining water from the Fuel Pro or when
ii. Start the engine. If this eliminates the air replacing the fuel filter) a check valve is needed to
bubbles, the air source is at the fuel tank keep the fuel system primed from the Fuel Pro back
fittings or hose connections. to the fuel tank. A check valve is standard with every
1. Tighten all fittings and connectors Fuel Pro
2. Retest A. To test for proper check valve operation,
remove the fuel inlet hose and open the vent
iii. If air bubbles persist, the air source is on
cap. Fuel should not flow out of the Fuel Pro ,
the Fuel Pro side of the system:
although a slight seepage of fuel is normal.
1. Tighten all fittings on the Fuel Pro .
B. If fuel drains back to the fuel tank, remove the
2. Hand tighten the top collar. check valve assembly at the fuel inlet fitting.
3. If the drain valve is suspected, install Disassemble the check valve assembly. Clean
a plug in place of the drain valve (for and inspect. Replace the assembly if any cuts,
test purposes only). grooves or nicks are evident in the ball or body
iv. If air bubbles continue to persist, test as seat. Reinstall the check valve assembly.
follows:
1. Remove the Fuel Pro from the chas-
sis.

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Diagnostic Procedures
Fluid Heater Thermovalve Test Electric Pre-Heater and Thermoswitch
Step 1: Drain the Fuel Pro completely. Tests
Step 2: Remove the fluid hoses going to the bottom plate.
These will either be engine coolant hoses or return fuel Equipment Needed:
hoses. Engine coolant hoses will have to be plugged when • A precision low resistance Ohm Meter capable of mea-
removing them from the Fuel Pro. suring 1/10th Ohm or less is recommended.
Step 3: Remove the bottom plate. • Current Flow Meter (Clamp-on type for DC current).
Step 4: While looking into the fluid port of the bottom plate • Ice, dry-ice, CO2 or some means of chilling the thermo-
(see Figure 9) flow cold water over the thermovalve for switch.
30 seconds, then run hot water over the thermovalve and • A flameless source of heat. Infrared heat lamp, etc. (a
determine if the thermovalve spool is opening and closing. Vortex tube is a good tool to heat and cool for testing).
Step 5: Replace with a new bottom plate seal and install EE DO NOT USE a test light that has a wire probe for
the bottom plate onto the Fuel Pro. any of these tests. If the insulation of the wiring is
Note: There are two styles of bottom plates. punctured, moisture and road salt can penetrate into
the wires creating a corrosion issue and potential
• Torque the collar version to 50 to 60 ft-lbs (the use of failure.
2-3 drops of Loctite 406 is recommended to secure the
bottom collar). Use seal P/N 101994. There are various configurations of electric pre-heaters and
thermoswitches available for the Fuel Pro. These include
• Torque the bolts on the bolt-on version bottom plate to 12 VDC pre-heaters, 24 VDC pre-heaters, 120 VAC pre-
10 ft-lbs. Use seal P/N 910005. heaters, thermoswitch, and combination pre-heater ther-
Step 6: Reconnect the fluid hoses to the bottom of the moswitch. The voltage and wattage ratings are stamped
Fuel Pro. either on the sheath or the hex of each component for
Step 7: Fill the Fuel Pro with fuel and restart the engine. identification.
If it is necessary to remove the fuel from the fuel/water
separator:
• Shut off the engine and set the parking brake.
• Attach a length of hose to the drain valve and into a
container.
Thermovalve
• Loosen the vent cap on top of the clear housing, and
open the drain valve to drain the fuel into the receptacle.
• When the fuel is drained, close the drain valve.

Pre-heater Test
Step 1: Disconnect the pre-heater from the harness.
Step 2: Connect the Ohm meter leads to the pins of the
pre-heater (connect to a pin and the bushing for pre-
heaters with one pin).
Port to view Step 3: Using the Table 2, read the value of the resistance
thermovalve and determine if the pre-heater is within the acceptable
spool range.

Figure 9

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Diagnostic Procedures
Electric Resistance Range Step 4: Prime the unit by filling the clear cover with clean
Watts diesel fuel until it reaches the top of the filter.
Pre-heater in Ohms
12 VDC (two pin) 250 W 0.6 to 0.8 Step 5: Install the vent cap. Hand tighten only.
Step 6: Start the engine and run for one minute. Slowly
12 VDC (single pin) 250 W 0.6 to 0.8
open the vent cap and allow the fuel to drop to about one
12 VDC (single pin) 150 W 0.8 to 1.1 inch above the collar. Close the vent cap. Hand tighten
only.
12 VDC (two pin) 150 W 0.8 to 1.1
24 VDC (two pin) 250 W 2 to 2.5
24 VDC (single pin) 250 W 1.8 to 2.3
24 VDC (single pin) 150 W 3.6 to 4.1
120 VAC 75 W 173 TO 203
120 VAC 37 W 369 TO 411
Table 2

12 VDC Thermoswitch Test

Step 1: Disconnect the thermoswitch harness (see Figure
10).
Step 2: Connect the Ohm meter leads to the pins of the
thermoswitch.

Figure 10
Note: This test requires the thermoswitch to be below 40°
F. (Use one of the cooling sources listed under "Equipment
Needed".) The resistance should be less than 0.1 Ohm.
Step 3: Using one of the heat sources listed under "Equip-
ment Needed", raise the temperature above 60° F. The
resistance should be more than 10M Ohms.

DAVCO Technology, LLC P. O. Box 487 Saline, MI 48176 Call 800-328-2611 www.davco.com F1271 REV C
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Check Valve Diagnostics

To test for proper check valve operation, remove the fuel Note: The spring retainer snaps into a groove in the check-
inlet hose and open the vent cap. Fuel should not flow out valve body.
of the Fuel Pro, although a slight seepage of fuel is normal. Step 5: Replace the check valve assembly into the body
If fuel drains back to the fuel tank, remove the check valve and torque to 44-60 ft-lb.
assembly at the fuel inlet fitting.
Step 6: . Connect the fuel inlet hose, using liquid or paste
Step 1: Use a back-up wrench to hold the check valve type thread sealant.
body and remove the fuel hose from the inlet of the Fuel
Pro. Step 7: Prime the fuel system, start the engine and check
for any fuel leaks.
Step 2: Remove and disassemble the check valve assem-
bly.
Check Valve Body Check Valve Service Kit
Step 3: Clean and inspect the check valve body. Replace
the check valve body if any cuts, grooves or nicks are
evident or if the ball seat is not smooth.
Step 4: Inspect the check valve spring and spring retainer.
If the spring or spring retainer is broken or if the check ball
has groves, nicks or is out of round, replace with a check
valve service kit. Otherwise, clean and reassemble the
check valve assembly. P/N 090037 P/N 101132

DAVCO Technology, LLC P. O. Box 487 Saline, MI 48176 Call 800-328-2611 www.davco.com F1271 REV C
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Service Parts
Service Parts Visit www.davco.com for OEM service part number listing.

Description Part Number

Collar 102425
Clear Cover 102420
Spring 380056 Collar
visit www.davco.com/parts.html
Filter Element Vent Cap Kit
for filter ordering information.
(part no. 240023DAV)
Drain Valve 102008 Includes Vent Cap
Electric Pre-heaters visit www.davco.com, Form F1263 with vent cap seal installed.

WIF See Page 20

Check valve body 090037
Spin-on stud
13/16"-12 320620
(Yellow Zinc)

Check Valve Body O-Ring Kit

Spring (part no. 380072)
Includes a vent cap seal
and a cover seal.

Filter
Check Valve Service Kit: P/N 101132

Service Kits
Description Contents Part Number
Vent cap and
Vent cap ser- Spin-on Stud
Vent cap 380043
vice kit
O-ring
O-ring Vent cap and Cover
380072
service kit O-rings
Check Valve
Retainer, spring and
Check valve Service Kit
ball (does not include 101132
service kit
the check valve body)
Drain Valve
DAVCO Wrenches OR
Description Part Number

Check Valve Body

Metal Col-
lar/Vent Cap 380134 Check Valve
Wrench Service Kit

Composite Heated
Collar/Vent 382002 Drain Valve
Cap Wrench

DAVCO Technology, LLC P. O. Box 487 Saline, MI 48176 Call 800-328-2611 www.davco.com F1271 REV C
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Service Parts
Bottom Plate - Service Kits and Parts
Description Part Number
Seal (Bottom Collar) 101994
Seal (Bolt-On) 910005

Unheated Bottom Plate (Bottom

382006SVC
Collar)

Fluid Heated Bottom Plate

382015SVC
(Bottom Collar)

Unheated Bottom Plate (Bolt-On) 382027SVCB

382029SVCB Standard

Bottom Plate Upgrade Includes:

Radiator o-rings (2) 382029SVCBE With ESOC port
Thermo-Valve Assembly
Bottom plate seal (square cut)
Spool assembly
With 1/2-20 WIF port and 3/8" Fluid
Bottom plate plug w/o-ring 382029-5SDAV
Port

With 1/2-20 WIF, 3/8" Fluid Ports and

382029-14DAV
Heater Port

Navistar Bottom Plate with 9/16"

382029NAV
Fluid Heat, Heater and WIF ports

Visit www.davco.com for OEM service part number listing.

DAVCO Technology, LLC P. O. Box 487 Saline, MI 48176 Call 800-328-2611 www.davco.com F1271 REV C
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Service Parts
Pre-heater - Service Parts

120 VAC Preheater 102145

120 VAC “Y” Cord 102015

120 VAC Straight Cord 101868

*Note: Visit www.davco.com, Form F1263 for 12VDC and 24VDC Pre-heaters.
For Specific OEM numbers for pre-heaters, contact customer support at 1-800-328-2611.

Water-in-Fuel (WIF) Service Parts

1 Pin WIF sensor 101017

2 Pin WIF sensor

102507
(Fleetguard and Bus Applications)

2 Pin WIF harness

102519
(17" Freightliner Chassis) Metripak

2 Pin WIF harness

102512
Deutsch (Grey)
2 Pin WIF harness
102521
Deutsch (Black)

2 Pin WIF 102770

2 Pin WIF with AMP Connector 102871

Visit www.davco.com for OEM service part number listing.

DAVCO Technology, LLC P. O. Box 487 Saline, MI 48176 Call 800-328-2611 www.davco.com F1271 REV C
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Warranty and Customer Service

PRODUCT WARRANTY
Fuel Pro 482, Fuel Pro 382, Diesel Pro 243, Industrial Pro, Shop Pro, Pro-Chek, Sea Pro and REN Products
DAVCO Technology, LLC warrants these products to be free of defects in material and workmanship for 5-years, 500,000
miles or 10,000 hours (whichever comes first) and electrical parts for 2-years, 200,000 miles or 4,000 hours (whichever
comes first) from the purchase date. Shop Pro Motor has a one year warranty from the date of purchase.
EyeMax, Electronic Gauges, Electronic Dipsticks, Fuel Pro 384
DAVCO Technology, LLC warrants these products to be free of defects in material and workmanship for 2-years or
200,000 miles (whichever comes first) from the purchase date.*
Limitation:
• DAVCO is not responsible for failures resulting from misuse, misapplication, faulty installation, alteration, poor main-
tenance, neglect or accident.
• DAVCO is not responsible for downtime, loss of profits or income, living expenses, or other incidental, special or
consequential damages.
• This warranty is the sole warranty made by DAVCO.
• DAVCO makes no other warranties, expressed or implied, of merchantability or fitness for a particular purpose.
• DAVCO does not warranty any aftermarket or OEM component not approved specifically to work with a DAVCO
manufactured product.
In the event of a defective product, DAVCO will either rework the defective product or replace it at DAVCO’s discretion. If
you feel you have a warrantable issue, contact DAVCO at 800-328-2611 for a Return Goods Authorization (RGA) number.
An RGA number is required prior to the return of any product.

*Purchase Date: The date of the first retail purchase of a new vehicle or piece of equipment from the OEM dealer or fac-
tory. For “Over the Counter” purchases: The date of the sale of a DAVCO product to the first retail customer.

PARTS RETURN GENERAL POLICY

Note: A Return Goods Authorization (RGA) must be obtained from DAVCO prior to returning any products. Returns may
be accepted under the following circumstances:
Order Shipping Error: A credit against the original invoice, including freight charges for both ways will be issued for re-
turns in which DAVCO inadvertently shipped incorrect quantity or product.
Overstock: Returns for ordering more product(s) than required, or incorrect part(s), will be accepted within 60 days from
the date of purchase. Proof of purchase will be required, IE: original invoice/delivery receipt. These types of return(s) are
subject to a minimum restock fee of 40% or $40.00, whichever is higher. Additional restock fees may apply. Product(s)
will be inspected for “like new” condition and additional costs will be the responsibility of the customer. No obsolete
parts may be returned.
Freight charges for return(s) will be the responsibility of the customer.

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