Fass Titanium Series Manual de usuario
INSTALLATION MANUAL
APPLICATION:
T D02 095G (95GPH @ 8-10psi)
T D02 150G (150GPH @ 8-10psi)
Cummins 5.9L 12 Valve
*with VE Pump*
1989-1993
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 em-
ploy 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. Remember price does
not dictate quality but quality does dictate price! Here at FASS, we believe it’s worth the commit-
ment and will continue this practice to support America! Our competition is doing exactly the op-
posite by using foreign-made components.
Building extremely “High-Quality” fuel products is our business. We concentrate all of our
efforts in this arena. No one else is as specialized as FASS in what we do! This is one of the ingre-
dients to insure you are running with the “Highest-Quality” fuel system in the world! We have im-
plemented very rigorous testing procedures to provide the “Highest Quality” we have become
known for. Not only is our product superior, but customer satisfaction is #1 at FASS. It is our goal
to provide the best service possible. Our confidence is evident in the products we make as each
product is backed by an industry leading warranty!
Our R & D department, in conjunction with our Dealer Support department, is continually
searching for ways to improve quality, expand our product line, and provide superb support to our
network of dealers so our customers’ needs and expectations will be exceeded.
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 prod-
uct immediately to that dealer and call FASS. We’ll recommend you to the nearest dealer.
VERY IMPORTANT: Make sure to fill out your product registration form and return the
original form to FASS Fuel Systems within 30 days of purchase accompanied with a copy of the
purchase receipt. Complying with these guidelines will qualify you for the Extended Warranty!
See the Owner’s Manual online at www.FASSride.com for full Limitation of Warranty. In
the event that the buyer does not agree with this agreement: the buyer may promptly return this
product, in a new and unused condition, with a dated receipt, 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 understands the
Limitation of Warranty agreement and accepts its terms and conditions.
Serial #
FASS Recommended Application
T D02 095G Cummins 1989-1993 with stock - moderate horsepower modifications
T D02 150G Cummins 1989-1993 with moderate - extreme horsepower modifications
Note: Because of the higher fuel flow these systems have to offer, you may encounter prob-
lems with the stock fuel module. FASS can solve this issue with a Suction Tube Kit.
¡WARNINGs!
Read all instructions before starting installation of this product!
Installing the improper FASS Pump can cause severe engine damage.
Secure vehicle from ROLLING!
Use caution when drilling. Steer clear of any electrical wires , air lines or other damageable
components.
Consult vehicle’s manufacturers’ instructions concerning the electrical system before at-
tempting any electrical connections.
Be sure that the serial # on this installation manual matches that of the outside of the box.
Flush and clean all brass fittings and fuel line from debris
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.
Wear safety glasses when operating power tools such as drills and grinders or when using a
punch or chisel.
Properly secure lines to prevent chaffing.
(T D02 095G or T D02 150G)
(T D02 095G or T D02 150G)
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 instal-
lation of this product indicates that the buyer has read and understands the limita-
tions 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. The installation recommendations contained herein are guidelines. Use good judg-
ment and take into consideration your vehicles' accessories.
4. 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 effi-
ciency. If a situation/problem arises during the installation, they are the most pre-
pared for that situation/problem. DPPI is not responsible for any installation mis-
takes.
5. If you have any questions or concerns that can not be addressed with your dealer,
email or call FASS.
6. If any installation procedure is uncertain, contact FASS technical support.
Email [email protected] with the following information:
Your Name, address and daytime phone number
Model
Serial Number
Last 6 of vehicles’ VIN
Date of purchase
Nature of Your Concern
Call customer service; 636-433-5410 with the following information:
Model
Serial Number
Last 6 of vehicles’ VIN
Date of purchase
Serial # Found
Titanium Series
Installation
Step 1: Install Electrical Harness
Step 2: Prepare Suction and Return Lines
Step 3: Mount Fuel System
Step 4: Install Fuel Line
Step 5: Check Installation
95 or 150 GPH
8 PSI (Approximately)
A fuel pressure gauge is highly recommended to identify fuel filter life and to prevent engine damage!
‘R’
Fuel Return to Tank
“E”
To Engine
Serial Number Location
‘G’
Fuel Pressure
‘T’
Fuel Inlet
Electric Heater
Port
“H”
Coolant Heater
2nd
Electric Heater Port
FL-1002 x17’
WH-1002
MP-9019
PFB-2001C
PBR-2001
Contents
Mounting Package ContentsMounting Package Contents
PL-1005
10-300 10-301 QD-1001
HC-1001
HC-1004
DIPF-1003
RM-1003
Ring Terminal
PL-2003
*WE-1001*
4 Hex Bolt 3/8” -16x 1 1/2” 3 Hex Bolt 1/4”-20x1 3/4”
4 Locking Nut 3/8”
3 WA-1001D 4 3/8” Washers
RS-2002 RS-2001
1 Hex Bolt 1/2” -20 x 1 1/2”
1 1/2” Washers
46260
46044
C. Crimp the ring terminals to the red and green wires of the WH-1005 Wire
Harness. Attach red wire to the positive terminal of the battery and the
green terminal to the negative terminal. The use of a corrosion preventa-
tive on electrical connections is recommended.
D. Secure relay and fuse in an upright position, as shown, to prevent
moisture from entering. Di-electric grease may be applied to prevent
corrosion.
FUSE
RELAY
Step 1: 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.
A. Using wire stripping tool remove excess insulation off the add-a-fuse
and the WH-1005.
B. Connect WE-1001 to the WH-1002. Place wire from 46044 and WE-1001 into butt connector. Using
crimping tool connect 46044 and WE-1001 with butt connector. Install 46260 to 46044 bottom slot
(opening that is near the spade). Route Add-a-fuse lead through the fire wall using existing grommet.
The use of corrosion preventative spray is recommended.
E. If fuse panel is located in the cab it will be necessary to guide the single
red wire from the relay through the fire wall grommet to access the fuse pan-
el.
G. Route WH-1002 wire harness along frame rail to mounting location of pump. Completion of this step
will be addressed in the Mounting Step 3.
Step 1: Install Electrical Harness
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 recom-
mended.
A. Prepare FASS return line by cutting rubber junction connecting the
two halves of the filler neck. Loosen the factory clamps at the tank.
Push the lower half filler neck into the tank enough to insert RM-1003.
As seen in the following photo.
B. Filler neck removed for clarity. Position RM-1003 with the 3/8” junc-
tion pipe aiming to outside of bed. Clamp rubber and RM-1003 using
both HC-1004’s and factory clamps.
D. Using a hose clamp install fuel line over the knurled flare on the QD-
1001. Oil O-rings inside Quick Disconnect.
C. Using a HC-1001 connect FL-1002 Fuel Line to the junction of RM-
1003.
D. Disconnect factory suction line clip by pressing in on the two tabs lo-
cated 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, will be addressed in step Installing Fuel
Line. Plug or seal factory line or remove. Bed has been removed for
photo clarity.
Step 2: Prepare suction & Return lines
Some of the photo’s are of a different application, procedures are the same.
Helpful Hint: If more space is required to access the top of the fuel
tank, loosen the strap nuts to the end of the stud. This will gain you
about 3” more working room.
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