Industrial Pro FH239 Series Filter/Separator/Warmer Installation Instructions

Transcription

1 ndustrial Pro FH239 eries Filter/eparator/Warmer nstallation nstructions K Cover ndustrial Pro ingle hort H W F P C J ottom owl G Vent Cap Filter lement (includes part C) R V Q Collar escription Vent Cap Vent Cap C -Ring P1053 Cover Filter pring umber Cover P1127 F Filter lement (includes C) F53015 G -Ring (includes C) H Priming Pump (includes solators) P1124 (2) Priming Pump Clamp and (4) crews P1133 J ndustrial Pro ee page 9 K racket with Fasteners P1131 (2) Priming Pump Hoses and (4) Fittings P1128 Plug 1/2" R P1125 ypass Check Valve P1121 iagnostic Plug Fitting P1130 P Water-n-Fuel (WF) ensor P1328 Q Check Valve P1120 R -Ring ottom owl rain Flange rain Valve V ottom racket and olts (8) ottom owl P1134 W Wrench P1076 ot hown WF Wiring Harness WF lectric Heater ee page 6 dapter Fitting, 3/4" to 1-1/4" dapter Fitting, 1-1/4" P to 42 x 1.5 P C: hese instructions are intended for use by professional mechanics who are trained in the proper use of power and hand tools, using appropriate safety precautions (including eye protection).

2 page 2 J Cover ndustrial Pro ingle all K P F Q C H G Vent Cap Filter lement (includes part C) R C Collar Vent Cap -Ring Cover Filter pring escription Vent Cap P1053 umber Cover P1127 F Filter lement (includes C) F53014 G -Ring (includes C) H ndustrial Pro ee page 9 racket with Fasteners P1132 J iagnostic Plug Fitting - xtended P1205 K Priming Pump (includes solators) P1124 Check Valve - xtended P1206 (2) Priming Pump Clamps and (4) crews (2) Priming Pump Hoses and (4) Fittings P1133 P1128 Plug 1/2" R P1125 P Check Valve P1120 Q Water-n-Fuel (WF) ensor P1328 R iagnostic Plug Fitting P1130 V -Ring ottom owl rain Flange rain Valve W ottom racket and olts (8) ottom owl and rain Valve P1134 X Wrench P1076 ot hown WF Wiring Harness WF lectric Heater ee page 6 dapter Fitting, 3/4" to 1-1/4" dapter Fitting, 1-1/4" P to 42 x 1.5 P X ottom owl V W

3 page 3 Cover ndustrial Pro ual all C Vent Cap Collar escription Vent Cap Vent Cap C -Ring P1053 F G Cover Filter pring Filter lement (includes C) -Ring umber Cover P1127 F53014 (includes C) H ndustrial Pro ee page 9 K F H G Filter lement (includes part C) J K racket with Fasteners iagnostic Plug Fitting - xtended Priming Pump (includes solators) Check Valve - xtended (2) Priming Pump Clamps and (4) crews (2) Priming Pump Hoses and (4) Fittings P1329 P1205 P1124 P1206 P1133 P1128 Plug 1/2" R P1125 P Check Valve P1120 Q Water-n-Fuel (WF) ensor P1328 R iagnostic Plug Fitting P1130 X P J Q R V W -Ring ottom owl rain Flange rain Valve ottom racket and olts (8) ottom owl P1134 ottom owl V W X Wrench P1076 WF Wiring Harness WF lectric Heater ee page 6 ot hown dapter Fitting, 3/4" P1135 to 1-1/4" dapter Fitting, 1-1/4" P to 42 x

4 page 4 Fuel Processor nstallation his system must be installed between the fuel tank and the transfer fuel pump on the suction side of the fuel system. WRG: When diesel fuel is circulated through an operating engine, it can become very hot. o prevent personal injury: calding hazard! o not allow heated liquid fuel to come in contact with eyes or unprotected skin. lways allow the engine and fuel to cool to ambient temperature before replacing the fuel filter or performing service operations which could result in the spillage of fuel from the fuel system. f this is not possible, protective clothing (face shield, insulated hat, gloves, apron) must be worn. Heated diesel fuel can form combustible vapor mixtures in the area around the fuel source. o eliminate the potential for fire, keep open flames, sparks or other potential ignition sources away from the work area, and do not smoke during filter replacement or service operations which could result in the escape of diesel fuel or fuel vapors. lways perform engine or vessel fuel system maintenance in a well ventilated area that is kept free of bystanders. C: o ensure priming pump hoses are not kinked by mishandling, do not lift or handle the fuel processor by the hoses. o not allow the weight of the processor to rest on the hoses. nstallation teps 1. With the engine shut down and at ambient temperature, close the fuel shutoff valve (if equipped) and place a suitable container under the fuel filters. 2. Remove the primary fuel filter element assembly, sedimenter, and/or water separator. rain the used element and dispose of it in an environmentally responsible manner, according to state and/or federal (P) recommendations. he fuel can be returned to the tank. nstallation of the ndustrial Pro should be on the suction side of the fuel system. o not exceed 2.2 lb/in 2 (15 kpa) inlet pressure to the fuel processor. 3. ount the ndustrial Pro in the desired location keeping the following points in mind: a. ounting the ndustrial Pro directly on the engine is RC. b. ount vertically with the cover and element pointing up. c. ake sure there is enough top and side clearance for the cover to be conveniently removed for filter replacement. d. Filter service clearance: ingle hort: 3.5" (89 mm) minimum ingle all: 6.0" (152 mm) minimum ual all: 6.0" (152 mm) minimum C: he ndustrial Pro functions when installed so that the Filter lement is above the "F" level of the fuel tank. he housing can be installed up to 6' (1.8 m) below the F level of the fuel tank. nstalling below the F level causes the starting level to be higher than normal. f mounted below full tank level, a shut off valve will be required at the inlet to allow filter changes without overflow of fuel. ounting below 6' (1.8 m) eliminates the G VG functionality. 4. Route the fuel supply line from the fuel tank to the ndustrial Pro inlet (see Figure 1). Route a fuel line from the ndustrial Pro outlet to the fuel pump inlet. C: o avoid fuel line water traps that can freeze in cold conditions and restrict, or block, the flow of fuel to the engine, be certain that there are no low spots in the hoses when routing them in the engine compartment.

5 page 5 o njectors/rail ow Pressure Pump High Pressure Pump n ngine Filtration Fuel ank Figure 1 - ndustrial Pro Connections ote: When the engine is shut off, fuel levels may drop until the engine is restarted. 5. o minimize restrictions, observe the following guidelines when plumbing the system. a. Keep the fuel line routing as smooth as possible with no low hanging loops which can trap water. b. se 90 elbows only when necessary. c. f the fuel hoses are made up to length on the job, be sure that the inner liner of the fuel hose is not cut by the fitting, creating potential check valve effects. lso make sure hoses are clean and free of debris before installing. C: o avoid damaging the aluminum fuel housing, do not overtighten fuel lines or line fittings. o not exceed 65 ft-lbs (88 m). ee the table of torque values on page pply liquid thread sealant to the inlet and outlet hose threads and connect the hoses to the unit. nstalling a WF (Water n Fuel) ensor With ptional ndicator () 1. nstall the WF Probe (P1328) into the side of the ndustrial Pro (see Figure 2). orque to in-lbs ( m). WF Probe Figure 2 - WF Probe nstallation 2. nstall the WF wiring harness ( ) on the WF Probe. he harness has the following connections: 12" (304.8 mm) black ground lead with a 3/8" (9.53 mm) diameter loop end and a 72" ( mm) green WF wire. 3. rill 1/2" (12.70 mm) hole in the control panel where the WF ( ) is to be located. a. nstallation must have 1.5" (38.10 mm) of clearance behind dash or control panel. b. se caution not to damage nearby components when drilling. 4. nstall WF by pressing firmly into the drilled hole. 5. Connect the 4" ( mm) black ground wire on WF to a ground source. ttach additional black wire as needed. 6. Connect the 12" (304.8 mm) black ground lead with a 3/8" (9.53 mm) diameter loop end on the WF wiring harness to ground source near Fuel Processor (if applicable). 7. Connect 72" ( mm) green signal wire on WF wiring harness to 4" ( mm) green signal wire on WF. se additional green wire as needed. 8. ocate 12 VC or 24 VC power source. Run red wire from power source to 4" ( mm) red wire on WF. dd a 1 in-line fuse (not included). (ee Figure 3.)

6 page 6 WF (Water- n-fuel) ensor WF ight ( ) Pre-heater Red Green WF Harness 1 Fuse Figure 3 - WF Wiring + ote: se appropriate connectors to attach the wires. o test the WF indicator, pour water into the body of the fuel processor until it covers the WF probe. he WF should illuminate. he volume of fluid necessary to turn the WF indicator on is 1500 ml. nstalling an ptional lectric Heater ll units come with pre-drilled ports to allow for preheaters (dual units require two pre-heaters): ingle hort: ne port ingle all: wo ports ual all: Four ports (two per body) able 1 12 and 24 VC Pre-heaters umber P1312 P1313 escription 12 VC Pre-heater 24 VC Pre-heater Figure 4 - Pre-heater nstallation o install, thread heater into housing and torque to ft-lbs ( m). Follow the wiring diagram in Figure 5. Refer to equipment owner's manual for more specific information related to wiring diagrams of the equipment to which the unit will be applied. ote: When wiring the electric pre-heater, use a fuse a circuit breaker. Without Relay attery attery Key Controlled Circuit 25 Fuse* Key Controlled Circuit 25 Fuse* 30/ ndustrial Pro *24 V heaters use 15 fuse (supplied in wire harness) ndustrial Pro With Relay se a relay if the available keyed circuit will not handle a minimum of 25. Relay *24 V heaters use 15 fuse (supplied in wire harness) Figure 5 Heater Wiring ptions For systems with multiple ndustrial Pro units, the pre-heater power supply wiring must be split in the Junction ox. ee Figure 6 for wiring a ual system.

7 page 7 Junction ox lack ual ystem o Circuit or Relay Red 6. nstall the new filter element. Figure 8 shows a key of the filter which fits into a keyway on the center boss. Position the filter element so the filter element key is lined up with the keyway on the center boss of the housing and press the filter element into the housing. nsure the filter element is fully seated by firmly pushing on the end plate. able 2 ndustrial Pro Replacement Filters o ndustrial Pros / Preheaters Figure 6 Wiring ual Filter ystems umber F53014 F53015 escription leax anoet 5 micron (tall) leax anoet 5 micron (short) Filter Change Procedure ote: Change the filter only when the fuel level reaches and remains at the top of the black band on the filter. he filter may become dark, however, there is additional filter capacity and restriction will remain low until the fuel reaches the black band. Key Keyway 1. urn off the engine. Remove the vent cap and dispose of the -ring. Clean the threads of the vent cap and on the top of the cover. et the vent cap aside. 2. pen the drain valve and drain the fuel completely from the unit, then close the drain valve. he unit must be completely drained to prevent contamination of the clean side of the filtration system. 3. sing the Collar Wrench (part number P1076), loosen the collar. Remove the clear cover and collar from the ndustrial Pro. iscard the cover -ring and install a new -ring (supplied with the filter) on the cover. Clean the threads on the collar and body of the ndustrial Pro. Figure 7 Collar/Vent Cap Wrench 4. nstall the new -ring on the vent cap (supplied with the filter). 5. Remove the filter element(s) from the ndustrial Pro by pulling upward. Figure 8 Key and Keyway 7. fter checking to make sure the new -ring seal is seated correctly on the base of the cover, install the cover and collar. imultaneously apply modest pressure to the top of the cover and turn the collar until it no longer spins freely. sing the collar wrench, tighten the collar the distance of two additional ribs. 8. Prime the fuel system according to the steps in the "Priming the Fuel ystem" section in this manual. (he vent cap will be returned to the ndustrial Pro during the priming process). Priming the Fuel ystem 1. Check to make sure the drain valve at the base of the ndustrial Pro is closed. Close the fuel shutoff valve (if equipped). 2. Remove the vent cap from the top of the clear cover. Fill the ndustrial Pro full of clean fuel. ighten the vent cap (tighten by hand only) until it clicks. 3. pen the fuel shutoff valve (if equipped). tart the engine. When the lubrication system reaches its normal operating pressure, increase engine speed to high idle for one to two minutes. oosen the vent cap until the fuel level drops to just above the collar. ighten the vent cap (tighten by hand only) until it clicks.

8 page 8 ote: he clear filter cover will not fill completely during engine operation. t will gradually fill over time and the fuel level will rise as the filter becomes clogged. raining Contaminants 1. urn off the engine and open the vent cap. 2. Place a suitable container under the drain valve at the base of the ndustrial Pro and open the drain valve. 3. Water and contaminants will flow into the container. When fuel begins to flow out of the drain, close the drain valve. 4. ighten the vent cap by hand until it clicks. 5. tart the engine. Raise the RP for one minute to purge the air from the system. ervicing the Primer Pump 1. Remove the fitting on the end of the pump using two wrenches to hold the end stationary as the fitting is loosened. 2. he washer on the fittings be in place when reassembled. uggested Preventive aintenance Weekly rain water. very Filter Change Change o-rings. very 12 onths Check all electrical connections for corrosion. Check all fuel fittings for leaks. xtreme winter or salt corrosion environments may require lubrication of the top collar threads with antiseize lubricant every 180 days. orque Values orque pplication in-lb ft-lb m WF Probe to Housing Fuel Connection Fittings to Housing ody Heater to Housing rain Valve to owl Primer Pump trap to ody Primer Pump Fittings to Housing ody Pump nlet/utlet Hose to Fittings to ounting racket Collar to ottom owl Washer Figure 9 Removing the Primer Pump Fitting

9 page 9 ndustrial Pro rdering nformation Housing umber Filter lement hort/ all Primer Pump WF Clear owl ingle racket ncluded Heater & Port ize FH23900 F53015 hort Yes Yes Yes Yes o n Right/ut eft 1-1/4" PF FH23904 F53015 hort Yes Yes Yes Yes o n eft/ut Right 1-1/4" PF FH23916 F53015 hort o Yes Yes Yes o n Right/ut eft 1-1/4" PF FH23917 F53015 hort o Yes Yes Yes o n eft/ut Right 1-1/4" PF FH23901 F53014 all Yes Yes Yes Yes o n eft/ut Right 1-1/4" PF FH23903 F53014 all Yes Yes Yes Yes o n Right/ut eft 1-1/4" PF FH23905 F53014 all Yes Yes Yes Yes o n eft/ut eft 1-1/4" PF FH23906 F53014 all Yes Yes Yes Yes o n Right/ut Right 1-1/4" PF FH23912 F53014 all o Yes Yes Yes o n Right/ut eft 1-1/4" PF FH23913 F53014 all o Yes Yes Yes o n eft/ut Right 1-1/4" PF FH23914 F53014 all o Yes Yes Yes o n eft/ut eft 1-1/4" PF FH23915 F53014 all o Yes Yes Yes o n Right/ut Right 1-1/4" PF ual FH23907 F53014* all Yes Yes Yes Yes o n Right/ut Right 1-1/4" PF FH23908 F53014* all Yes Yes Yes Yes o n Right/ut eft 1-1/4" PF FH23910 F53014* all Yes Yes Yes Yes o n eft/ut Right 1-1/4" PF FH23911 F53014* all Yes Yes Yes Yes o n eft/ut eft 1-1/4" PF FH23918 F53014 all o Yes Yes Yes o n Right/ut eft 1-1/4" PF FH23919 F53014 all o Yes Yes Yes o n eft/ut Right 1-1/4" PF FH23920 F53014 all o Yes Yes Yes o n eft/ut eft 1-1/4" PF FH23921 F53014 all o Yes Yes Yes o n Right/ut Right 1-1/4" PF * Requires two filter elements ndustrial Pro pecifications pecification ingle hort ingle all ual all Height verall 20" (508 mm) 28" (711 mm) 28" (711 mm) epth verall 12" (305 mm) 12" (305 mm) 12" (305 mm) Width, max 11.2" (284 mm) 13.9" (352 mm) 23.8" (604 mm) Weight (ry) 29 lbs (13.2 kg) 39 lbs (17.7 kg) 75 lbs (34.0 kg) Weight (Wet) 37 lbs (16.8 kg) 57 lbs (25.6 kg) 112 lbs (50.8 kg) Fuel Capacity (w/o filter) 1.1 gal (4.3 ) 2.5 gal (9.5 ) 5.0 gal (19 ) Fuel Connections 1-1/4" P 1-1/4" P 1-1/4" P Fuel Flow Rate 300 gal/hr (12.6 /min) 600 gal/hr (37.9 /min) 1200 gal/hr (63.1 /min) ottom owl Water Holding Capacity 29 fl oz (860 ml) 29 fl oz (860 ml) 58 fl oz (1720 ml) Filter ervice Clearance in. 3.5" (89 mm) in. 6.0" (152 mm) in. 6.0" (152 mm) lectrical Heater ptions 12 VC or 24 VC 12 VC or 24 VC 12 VC or 24 VC Primer Pump upply Voltage: 24 VC, 6 upply Voltage: 24 VC, 6 upply Voltage: 24 VC, 6 Fuel ypes Compatible for use with iesel #1, iesel #2, Kerosene, iodiesel 20, and JP8 pecifications subject to change without notice.

10 page 10 imensions ndustrial Pro ingle hort ervice Height 3.5 (88.9) (273.8) 1.50 (38.1) (508.0) ax (64.1) 0.32 (8.0) 2.75 (69.9) 2.75 (69.9) 7/8"-14 F-2 ptional Heater -Ring oss Port 1.50 (38.1) ll dimensions are in inches (millimeters) 7/8"-14 F-2 ptional Heater -Ring oss Port 0.75 (19.1) WF ensor /4"-11-1/2 PF 14 iagnostic Port ptional (195.6) (38.1) 6.60 (167.6) 0.55 (14.0) 0.92 (23.4) 5.20 (132.1) 1.08 (27.4) 2.00 (50.8) 7.75 (196.8) 5.97 (151.6) 0.22 (5.6) 1-1/4"-11-1/2 PF (x4) 0.75 (19.1) 6.00 (152.4) 8.20 (208.3) 0.35 (8.9) iagnostic Port ptional 0.32 (8.0) 2.00 (50.8) (eft-n, Right-ut nit hown) ndustrial Pro ingle all ervice Height 6.0 (152.4) 4.20 (106.7) 1-1/4"-11-1/2 PF (302.8) 2.77 (70.5) (701.1) ax (211.3) ll dimensions are in inches (millimeters) 0.35 (8.9) 1.50 (38.1) 9.56 (242.7) 0.52 (13.2) 14 iagnostic Port ptional 5.08 (128.9) 5.97 (151.6) 14 iagnostic Port ptional 2.77 (70.5) 0.22 (5.6) (x12) (38.1) (242.7) 2.20 (55.9) 3.50 (88.9) 8.96 (227.6) ( (316.5) 0.55 (14.0) 1.20 (30.5) 2.00 (50.8) (351.8) (195.6) (167.6).040 7/8"-14 F-2 ptional Heater -Ring oss Port 7.75 (196.8) 4.20 (106.7) /8"-14 F-2 ptional Heater -Ring oss Port 1-1/4"-11-1/2 PF 2.00 (50.8) (eft-n, Right-ut nit hown) ndustrial Pro ual all ervice Height 6.0 (152.4) (106.7) (128.9) ll dimensions are in inches (millimeters) 1-1/4"-11-1/2 PF (302.8) 2.77 (70.5) 0.35 (8.9) 1.50 (38.1) (701.1) ax (14.0) 0.50 (12.7) 7/8"-14 F-2 ptional Heater -Ring oss Port 14 iagnostic Port ptional 1.20 (30.5) 2.00 (50.8) (322.3) 5.97 (151.6) 7.75 (196.8) 14 iagnostic Port ptional (577.9) 0.22 (5.6) (x12) 7.70 (195.6) 6.60 (167.6) 8.32 (211.3) 4.20 (106.7) (70.5) (38.1) 9.56 (242.7) 2.20 (55.9) 8.96 (227.6) (316.5) (488.2) (544.1) 1-1/4"11-1/2 PF 7/8"-14 F-2 ptional Heater -Ring oss Port 2.00 (50.8) (eft-n, Right-ut nit hown) For more information, visit cumminsfiltration.com Rev Cummins Filtration nc. Printed in the...