A FH235 Cover Assembly Includes Vent Cap, Vent Cap O-Ring, Collar, Cover, Cover O-Ring, and Spring F E C D I Diesel Pro 235 Diesel Pro FH235, FH236 and FH241 Series Filter/Separator/Warmer Installation Instructions B Biodiesel O-Ring Pack Includes Vent Cap O-Ring and Cover O-Ring J F H K G Bottom Bowl Assembly Includes Bottom Bowl Seal, Bottom Bowl, Screws, Drain Valve O-Ring, and Drain Valve Manual Primer Pumps Parts List Part Description Part Number A FH235 Cover Assembly (includes Vent Cap, Vent Cap O-Ring, Collar, Cover, Cover O-Ring, and Spring) 3973506 S B Biodiesel O-Ring Pack only required for >B5 fuel (includes Vent 3950444 S Cap O-Ring and Cover O-Ring) C Filter Element See page 9 D Check Valve AssemblySP1413 E Diesel Pro FH235, Unheated See page 12 F Adapter - 7/8"-14 to M16 x 1.5 3973689 S Adapter - 7/8"-14 to 3/8" NPT 3980209 S G H Pre-Heater, 12 V, 195 W, WP Connector Pre-Heater, 24 V, 195 W, WP Connector Pre-Heater, 24 V, 195 W, Tyco Connector 120 VAC, 75 W Heater Bottom Bowl Assembly (includes Bottom Bowl Seal, Bottom Bowl, Screws, Drain Valve O-Ring, and Drain Valve) SP1312 SP1313 SP1314 3980208 S 3972255 S I Water-In-Fuel (WIF) Sensor3957158 S J Collar for Reduced Clearance Applications (optional) 3945059 S K Collar Wrench, Metal3944458 S Not Shown WIF Wiring Harness WIF LED 3950729 S 3946670 S L Manual Primer Pump Plunger 3975110 S M N Primer Pump Check Valve (M16) Primer Pump Check Valve (M18) Primer Pump Check Valve (3/8") Primer Pump Check Valve (7/8") Primer Pump Service Kit (M16) Primer Pump Service Kit (M18) Primer Pump Service Kit (3/8") 3981659 S 3981660 S SP1642 3975109 S 3979203 S 3979202 S SP1632 O Primer Pump Service Kit 3975111 S P Check Valve Assembly (M18) Check Valve Assembly (M16) Check Valve Assembly (7/8") Check Valve Assembly (3/8") SP72127 SP72128 SP72129 SP72130 Q Check Valve Assembly Kit SP1644 M O L N L P Q CAUTION: These 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).
page 2 Diesel Pro 236 Parts List Part Description Part Number A FH236 Cover Assembly includes Vent Cap, Vent Cap O-Ring, Collar, Cover, Cover O-Ring, and Spring) 3974145 S A FH236 Cover Assembly Includes Vent Cap, Vent Cap O-Ring, Collar, Cover, Cover O-Ring, and Spring B Biodiesel O-Ring Pack Includes Vent Cap O-Ring and Cover O-Ring B Biodiesel O-Ring Pack only required for >B5 fuel (includes Vent 3950444 S Cap O-Ring and Cover O-Ring) C Filter Element See page 9 D Check Valve Assembly SP1413 E Diesel Pro FH236, Unheated See page 12 F G Adapter - 7/8"-14 to M16 x 1.5 Adapter - 7/8"-14 to 3/8" NPT Pre-Heater, 12 V, 195 W, WP Connector Pre-Heater, 24 V, 195 W, WP Connector Pre-Heater, 24 V, 195 W, Tyco Connector 120 VAC, 75 W Heater 3973689 S 3980209 S SP1312 SP1313 SP1314 3980208 S H Bottom Bowl Assembly (includes Bottom Bowl Seal, Bottom Bowl, Screws, Drain Valve O-Ring, and Drain Valve) 3972255 S I Water-In-Fuel (WIF) Sensor3957158 S C K J Collar for Reduced Clearance Applications (optional) 3945059 S K Collar Wrench, Metal3944458 S Not Shown WIF Wiring Harness3950729 S WIF LED3946670 S F E D I J F H G Bottom Bowl Assembly Includes Bottom Bowl Seal, Bottom Bowl, Screws, Drain Valve O-Ring, and Drain Valve L Manual Primer Pump Plunger 3975110 S M N Primer Pump Check Valve (M16) Primer Pump Check Valve (M18) Primer Pump Check Valve (3/8") Primer Pump Check Valve (7/8") Manual Primer Pump (M16) Manual Primer Pump (M18) Manual Primer Pump (3/8") 3981659 S 3981660 S SP1642 3975109 S 3979203 S 3979202 S SP1632 O Primer Pump Service Kit 3975111 S P Check Valve Assembly (M18) Check Valve Assembly (M16) Check Valve Assembly (7/8") Check Valve Assembly (3/8") SP72127 SP72128 SP72129 SP72130 Q Check Valve Service Kit SP1644 Manual Primer Pumps M O L N L P Q
page 3 Diesel Pro 241 Parts List FH241 Cover Assembly Includes Vent Cap, Vent Cap O-Ring, Collar, Cover, Cover O-Ring, and Spring J R A M E C H F D B G I Part Description Part Number A FH241Cover Assembly includes Vent Cap, O-Ring, Collar, Cover, Cover O-Ring, 3974145 S and Spring) B O-Ring Pack (Vent Cap and Collar)3945061 S C Filter Element See page 9 D Vent Cap Service Kit SP1053 E Filter Spring 3944441 S F Reduced Clearance Collar 3945059 S G Diesel Pro FH241, Unheated See page 13 H Adapter - 7/8" to M16 Adapter - 7/8" to M18 Adapter - 7/8" to 3/8" 3973689 S SP1643 3980209 S I Drain & Cap SP1647 J Pre-Heater, 24V, 195 W, Tyco Connector Pre-Heater, 24V, 195 W, WP Connector Over Night Heater, 120 V SP1314 SP1313 3945121 S K Water-In-Fuel (WIF) Sensor 3957158 S WIF Wiring Harness3950729 S WIF LED3946670 S Not ESOC/Drain Valve SP1645 Shown Drain Valve Service Kit SP1646 WIF Port Plug SP1125 L Manual Primer Pump Pump 3975110 S M N Primer Pump Check Valve (M16) Primer Pump Check Valve (M18) Primer Pump Check Valve (3/8") Primer Pump Check Valve (7/8") Primer Pump Service Kit (M16) Primer Pump Service Kit (M18) Primer Pump Service Kit (3/8") 3981659 S 3981660 S SP1642 3975109 S 3979203 S 3979202 S SP1632 O Primer Pump Service Kit 3975111 S P Check Valve Assembly (M18) Check Valve Assembly (M16) Check Valve Assembly (7/8") Check Valve Assembly (3/8") SP72127 SP72128 SP72129 SP72130 Q Check Valve Service Kit SP1644 K R Collar Wrench, Metal 3944458 S Manual Primer Pumps O L N L P Q
page 4 Introduction How It Works Fuel from the tank enters the Diesel Pro 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 and with lowest restriction. Clean, water-free fuel exits the Diesel Pro and flows to the lift pump. 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 95% of free and emulsified water. This performance far exceeds that of cellulose media. Vent Cap Media Coalescent Layer Hydrophobic Layer Water Sump Dirty Side Drain Valve (ESOC Compatible) Fuel OUT Water Sump Clean Side 1 2 3 4 Figure 1 - Seeing Is Believing 1. When new, the fuel level in the filter will be very low with minimal restriction. As the filter is used, contaminants collect on the filter from the bottom up. Fuel rises on the filter indicating remaining filter life. 2. Fuel level increases in clear cover. As contaminants collect on the filter, the fuel rises to a non-contaminated section of the filter, providing optimal filtration while maintaining lowest restriction. 3. Fuel level at filter wrap level. Even though the fuel level is now more than half of the filter element, the fuel is still flowing through clean media at minimal restriction levels. The filter still has significant life remaining. 4. The filter element is now completely covered by fuel. At this point, all of the media s surface area is utilized. Restriction is increasing and the filter element should be changed at the next scheduled maintenance interval. FH241 Series Advanced Water Separation Architecture The FH241 Series has a new water separation architecture providing higher water separation performance than the FH235 or FH236 series. The FS20081 cartridge has additional coalescing and hydrophobic layers that provide the performance required for T4F and EPA2017 midrange engines. The new water separation concept introduces two additional steps (coalescing on an additional layer, repelling on a hydrophobic layer), improving overall water separation performance.
page 5 Service Kit Installation This system must be installed between the fuel tank and the transfer fuel pump. If approved by the manufacturer, this system can be used as the only fuel filter in the fuel system by removing the existing filter and heads, or by removing the filters only and replacing them with special Diverter Caps (sold separately - see Table 1). Note: If the Diesel Pro is used as the primary filter and a secondary filter is required, secondary filter life may be extended. Diverter Cap Part Number Table 1 - Diverter Caps Required Filter Head Stud Size Required Filter Head Seal ID in (mm) Required Filter Head Seal OD in (mm) 3945182 S 1"-14 2.475 (62.865) 2.895 (73.533) 3945183 S 1"-14 3.225 (81.915) 3.435 (87.249) 3945184 S M16 x 1.5 2.475 (62.865) 2.895 (73.533) 3945185 S 3/4" x 16 2.475 (62.865) 2.895 (73.533) 3945186 S 7/8" x 14 2.475 (62.865) 2.895 (73.533) WARNING: When diesel fuel is circulated through an operating engine, it can become very hot. To prevent personal injury: Scalding hazard! Do not allow heated liquid fuel to come in contact with eyes or unprotected skin. Always 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. If this is not possible, protective clothing (face shield, insulated hat, gloves, apron) must be worn. Fire hazard! Heated diesel 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, and do not smoke during filter replacement or service operations which could result in the escape of diesel fuel or fuel vapors. Inhalation hazard! Always perform engine or vessel fuel system maintenance in a well ventilated area that is kept free of bystanders. The ignition key must be in the OFF position. Installing the Diesel Pro Service Kit 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. Drain the used element and dispose of it in an environmentally responsible manner, according to state and/or federal (EPA) or national recommendations. The fuel can be returned to the tank. 3. For a one-filter system, select the required secondary filter head diverter cap from those listed in Table 1. The required part number is determined by the size of the spin-on filter stud and the filter sealing surface diameter. Install the diverter cap on the secondary filter head as follows: a. Remove the secondary fuel filter element, drain and dispose of it in an environmentally responsible manner according to government regulations (i.e., state/province, federal, etc.). The fuel can be returned to the tank. b. Lightly lubricate the seal on the top of the diverter cap with clean engine oil. c. Thread the adapter onto the secondary filter stud and tighten by hand only. d. Install the "Do Not Remove" sticker on the diverter cap. 4. Mount the Diesel Pro in the desired location using 3/8" (9.5 mm) Grade 8 hardware. Keep the following points in mind: a. Mounting the Diesel Pro directly on the engine is NOT RECOMMENDED. b. Mount vertically with the cover and element pointing up. c. Make sure there is enough top and side clearance for the cover to be conveniently removed for filter replacement (1.5" (38.1 mm) minimum). d. Bolt spacing is 5.25" (133.35 mm). CAUTION: The Diesel Pro MUST be installed so that the Filter Element is above the "FULL" level of the fuel tank. If mounted below full tank level, a shut off valve will be required at the inlet to allow filter changes without overflow of fuel.
page 6 5. Route the fuel supply line as follows (see Figure 2): a. Route the fuel supply line from the pickup on the fuel tank to the Diesel Pro inlet (labeled Fuel In ). b. Route the fuel outlet line from the Diesel Pro outlet (labeled Fuel Out ) to the inlet of the fuel pump. Diesel Pro b. Use 90 elbows only when necessary. c. If 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. Also make sure hoses are clean and free of debris before installing. CAUTION: To avoid damaging the aluminum fuel processor body, do not overtighten fuel lines or fuel line fittings. 7. If an electrical heater is required, see page 6, Installing an Optional Electric Heater. Fuel Tank IN Lift Pump Injection Pump Figure 2 Diesel Pro Connections Note: The inlet and outlet fittings can be moved from side to side depending on the application. For example, in Figure 3 the FUEL IN is on the right and the FUEL OUT is on the right. Be sure to use only ONE INLET and ONE OUTLET port per installation. (Tighten adapter fittings and plugs to 25-40 ft-lbs (2.8-4.6 N m).) Installing a WIF (Water In Fuel) Probe 1. Remove the 1/2"-20 WIF plug from the bottom of the Diesel Pro. 2. Install the WIF Probe (3957158 S) into the bottom of the Diesel Pro (see Figure 4). Torque to 20-24 in-lbs (2.3-2.8 N m). 3. Install the WIF wiring harness (3950729 S) on the WIF Probe. The harness has the following connections: black ground lead with a 3/8" (9.53 mm) diameter loop end and a green WIF wire. WIF Probe HEATER Figure 3 Fuel Line Inlets and Outlets 6. To 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. Figure 4 WIF Probe Installation 4. Drill a 1/2" (12.70 mm) hole in the dash or control panel where the WIF LED (3946670 S) is to be located. a. Installation must have 1.5" (38.10 mm) of clearance behind dash or control panel. b. Use caution not to damage nearby components when drilling. 5. Connect the black ground wire on WIF LED to a ground source. Attach additional black wire as needed.
page 7 6. Install WIF LED by pressing firmly into the drilled hole. 7. Connect the black ground lead with a 3/8" (9.53 mm) diameter loop end on the WIF wiring harness to ground source near the Diesel Pro (if applicable). 8. Connect green signal wire on WIF wiring harness to 4" (101.60 mm) green signal wire on WIF LED. Use additional green wire as needed. 9. Locate a 12 VDC or 24 VDC power source. Run a red wire from power source to the red wire on WIF LED. Add a 1 A in-line fuse (not included). (See Figure 5). Figure 5 WIF Wiring Note: Use appropriate connectors to attach the wires. To test the WIF indicator, pour water into the body of the fuel processor until it covers the WIF probe. The WIF LED should illuminate. Installing an Optional Electric Heater All units come with pre-drilled ports to allow for heaters/thermostats. The electric heaters available for the Diesel Pro are 12 or 24 VDC Combo Thermo/Heaters and 120 VAC Heater. Electric heaters are optional and must be ordered separately (see Table 2). Table 2 Electric Heaters Part Number Description SP1312 Pre-Heater, 12 V, 195 W, WP Connector SP1313 Pre-Heater, 24 V, 195 W, WP Connector SP1314 Pre-Heater, 24 V, 195 W, Tyco Connector 3945121 S 120 VAC, 75 W Heater 3980208 S 120 VAC, 75 W Heater 1. If an Electric Heater is not already installed, remove the 7/8"-14 SAE (M16 x 1.5) o-ring heater plug from the Diesel Pro and install the Heater. Torque to 25-40 ft-lbs (2.8-4.6 N m). (See Figure 6.) PTC Heater Figure 6 - Heater Installation 2. Connect the Chassis harness to the Diesel Pro harness. 3. Attach the grounding eyelet to the chassis using a suitable 3/8" (9.5 mm) bolt. 4. Connect the Power Lead to the accessory side of the ignition switch. (Use of a 15 A fuse is recommended, but not included in the Diesel Pro kits. Use a relay if the ignition circuit will not handle a minimum of 15 A.) (See Figure 7.) Figure 7 Fuse and Relay Connections Installing Optional Priming Pumps The Fleetguard Manual Priming Pump must be installed on the suction side of the fuel system. CAUTION: Do not over tighten the fuel hoses to the fittings to avoid damage to the Priming Pump or filter housing.
L4758 Covered under one or more of the following U.S. patents: 4368716, 4428351, 5507942, RE37165 E, and foreign patents or others pending. page 8 Installing with a New Diesel Pro Produced Before August 30, 2010 or Any Diesel Pro Without a Bottom Bowl 1. Disconnect the fuel inlet line coming from the fuel tank to the Diesel Pro inlet. 2. Thread the T shaped plunger pump from kit #3979202 S (M18) or 3979203 S (M16) into the Fuel Inlet Port of the Diesel Pro. 3. Attach the fuel line from the fuel tank to the inlet of the Primer Pump. 4. Tighten to 25-40 ft-lb (39.9-54.3 N m) of torque. 5. Remove the vent cap from the Diesel Pro. 6. Cycle the plunger of the Priming Pump until the Diesel Pro is full of fuel. 7. Hand tighten the vent cap. 8. Start the engine. When the lubrication system reaches normal operating pressure, increase the RPM for one minute. Slowly open the vent cap until the fuel level drops to one inch above the collar. 9. Check for fuel leaks. 10. Installation is complete. Diesel Pro Priming Pump (3979202 S or 3979203 S) 2. Thread the Check Valve (3975109 S) from kit 3975111 S into the inlet port of the Diesel Pro. 3. Reconnect the fuel line from the fuel tank to the Diesel Pro inlet with Check Valve in place. 4. Remove the plug from the free Fuel Inlet Port. 5. Thread the Plunger Assembly (3975110 S) from kit 3975111 S into the free Fuel Inlet Port. 6. Tighten to 25-40 ft-lb (39.9-54.3 N m) of torque. 7. Remove the vent cap from the Diesel Pro. 8. Cycle the plunger of the Priming Pump until the Diesel Pro is full of fuel. 9. Hand tighten the vent cap. 10. Start the engine. When the lubrication system reaches normal operating pressure, increase the Revolutions Per Minute (RPM) for one minute. Slowly open the vent cap until the fuel level drops to one inch above the collar. 11. Check for fuel leaks. 12. Installation is complete. Plunger Assembly (3975110 S) Diesel Pro Check Valve (3975109 S) Diesel Pro FH235 Series OUTLET INLET Fuel Line Note: Housings without the bottom bowl feature can use only the style priming pump shown here Fuel Tank Fuel Tank Figure 9 Installing the Priming Pump with a Diesel Pro Produced After August 30, 2010 Figure 8 Installing the Priming Pump with a Diesel Pro Produced Before August 30, 2010 Installing with a New Diesel Pro Produced After August 30, 2010 With a Bottom Bowl With the engine shut down and at ambient temperature, close the fuel shut-off valve (if equipped) and place a suitable container under the Diesel Pro and drain the fuel until empty. Filter Change Procedure 1. Remove the vent cap and open the drain valve to drain the fuel below the collar level. 2. Remove the collar using the Collar/Vent Cap Wrench (3944458 S) then remove the clear cover. 1. Disconnect the fuel inlet line coming from the fuel tank to the Diesel Pro inlet.
page 9 Figure 10 Collar/Vent Cap Wrench 3. Remove the filter, cover, and vent cap seals. Dispose of the filter and the seals properly. 4. Using a clean rag, clean the cover, the collar, and threads on the Diesel Pro body. 5. Install a new filter, cover seal, and vent cap seal. 6. Reinstall the clear cover and collar. Hand tighten the collar. 7. Prime the unit by filling the clear cover with clean diesel fuel until it reaches the top of the filter. 8. Install the vent cap. Hand tighten only. 9. Start the engine and run for one minute. Slowly open the vent cap and allow the fuel to drop to about one inch (32 mm) above the collar. 10. Close the vent cap. Hand tighten only. It is normal for the fuel level to vary after the initial start-up and during engine operation. Filter performance is not affected. Table 3 Replacement Filters Diesel Pro 235 Part Number Description FS19730 StrataPore 7 micron FS19731 StrataPore 10 micron FS19785 StrataPore 25 micron Priming the System The Diesel Pro fuel processor must be filled with clean fuel before the filtering system will operate properly. Use the following procedure to prepare the Diesel Pro for service. 1. Check to make sure the drain valve at the base of the Diesel Pro is closed. 2. Remove the vent cap from the top of the clear cover. 3. Fill the Diesel Pro full of clean fuel. 4. Reinstall the vent cap and tighten by hand only. 5. Start the engine. 6. When the lubrication system reaches its normal operating pressure, increase engine RPM to high idle for one to two minutes. After the air is purged, loosen the vent cap until the fuel level lowers to just above the collar. Retighten the vent cap by hand only. 7. Hand tighten the collar again while the engine is running. CAUTION To avoid damage, do not use tools to tighten the collar. Note: The clear filter cover will not fill completely during engine operation. It will gradually fill over time and the fuel level will rise as the filter becomes plugged. Table 4 Replacement Filters Diesel Pro 236 Part Number Description FS19761 EleMax StrataPore 5 micron FS19624 EleMax StrataPore 7 micron FS19729 EleMax Cellulose 50 micron FS19728 EleMax StrataPore 25 micron FS19727 EleMax StrataPore 10 micron Table 5 Replacement Filters Diesel Pro 241 Part Number Description FS20081 EleMax StrataPore 10 micron
page 10 Suggested Preventive Maintenance Weekly Drain water 1. Turn off the engine and open the vent cap. 2. Place a suitable eight ounce plastic or metal container under the drain valve at the base of the Diesel Pro and open the valve. 3. Water will flow into the container. When the fuel begins to flow out the drain, close the drain valve. Drain the least amount of fuel possible. 4. Hand tighten the vent cap. 5. 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 filter service kit). Every 12 Months Check all electrical connections for corrosion. Check all fuel fittings for leaks. Extreme winter or salt corrosion environments may require lubrication of the top collar threads with Loctite 76747 anti-seize every 180 days. Servicing the Check Valve Assembly 1. Remove the vent cap and open the drain valve, drain the Diesel Pro completely. 2. Remove the collar, then remove the clear cover. 3. Remove the filter, cover and vent cap seals. Dispose of filters and seals properly. 4. Using a clean shop rag, clean the cover, the collar and threads on the Diesel Pro body. 5. Remove the check valve assembly (see Figure 11). 6. Clean and inspect the check valve body (Replace if the valve or the seat show any visible signs of damage) 7. Replace the check valve assembly into the Diesel Pro body (torque to 12-14 ft-lbs). 8. Install a new filter, cover seal and vent cap seal. 9. Reinstall the clear cover and collar. Tighten the collar. 10. Prime the Diesel Pro by filling the clear cover with clean diesel fuel until it reaches the top of the filter. 11. Install the vent cap. 12. Start the engine and run for one minute. Slowly open the vent cap and allow the fuel level to drop to about one inch above the collar. 13. Close the vent cap. Hand tighten only. Troubleshooting Every Diesel Pro is factory tested for leaks and is marked with a traceable number to show that it has passed production testing. Most field issues associated with leaks are related to loose fittings. These leaks are easily eliminated by checking and torquing the fuel fittings in the area of the leak. Some fittings may also require the application of liquid Teflon sealer. Note: All suction side fuel filters experience bubbles. It is normal to see champagne size bubbles in the Diesel Pro at the Diesel Pro outlet or at the lift pump. Figure 11 Removing the Check Valve Assembly
page 11 Air Leak Air bubbles will be visible in the clear cover of the Diesel Pro if the leak originates from the fuel tank up to the fuel filter. The following is a quick test to isolate the air leak source. Bubbles Visible: 1. Remove the Diesel Pro inlet hose. 2. Install a jumper hose from the Diesel Pro to the fuel tank (through the fill cap) or to a container of fuel. 3. Start the engine. If this eliminates the air bubbles, the air source is at the fuel tank fittings or hose connections. 4. Tighten all fittings and connectors 5. Retest If air bubbles persist, the air source is on the Diesel Pro side of the system: 1. Tighten all fittings on the Diesel Pro. 2. Tighten the collar. 3. If the drain valve is suspected, install a plug in place of the drain valve (for test purposes only). If air bubbles continue to persist, test as follows: 1. Remove the Diesel Pro from the chassis. 2. Plug the fuel inlet port. Do not remove filter, cover/collar, vent cap, drain valve and/or check valve. If the Diesel Pro is equipped with a preheater, do not remove the preheater. 3. Apply 15 PSI of air pressure at the fuel outlet. Immerse the Diesel Pro in a tank of water and look for air bubbles. 4. Correct the source of the air leak and retest. Bubbles Not Visible Excessive Restriction If the fuel level is at the top of the filter, replace the fuel filter. The Diesel Pro will not cause excess system restriction if the fuel level is below the top of the filter. Loss of Prime When air is introduced into the fuel system, (for example, when draining water from the Diesel Pro or when replacing the fuel filter) a check valve is needed to keep the fuel system primed from the Diesel Pro back to the fuel tank. A check valve is standard with all Diesel Pros. To test for proper check valve operation: Remove the fuel inlet hose and open the vent cap. Fuel should not flow out of the Diesel Pro, although a slight seepage of fuel is normal. If fuel drains back to the fuel tank, remove the check valve assembly: 1. Disassemble the check valve assembly. Clean and inspect. 2. Replace the assembly if any cuts, grooves or nicks are evident in the valve or valve seat. 3. Reinstall the check valve assembly. 1. If there are symptoms of sucking air (indicated by engine loping/rough running performance/ power loss, etc.) and there are no bubbles in the clear cover, the air leak is either at the Diesel Pro outlet fitting, vent cap o-ring, the lift pump inlet connection, or the fuel hose/connections to the lift pump. 2. Inspect and tighten fittings as needed.
page 12 Ordering Information Diesel Pro 235 Housing Part Number Filter Element Heater WIF Cover Fuel Flow Fuel In & Fuel Out Port Size Priming Pump FH23500FS19730 N/A N/A Short In Right/Out Left 7/8"-14 No FH23501FS19730 24 VDC, 195 W N/A Short In Right/Out Left 7/8"-14 No FH23502FS19730 12 VDC, 195 W N/A Short In Right/Out Left 7/8"-14 No FH23503 M* FS19785 N/A Yes Short In Right/Out Left M16 No FH23504 M*FS19785 24 VDC, 195 W Yes Short In Right/Out Left M16 No FH23506FS19731 24 VDC, 195 W Yes Short In Right/Out Left 7/8"-14 No FH23508FS19731 N/A Yes Short In Right/Out Left 7/8"-14 No FH23509 M*FS19731 N/A Yes Short In Right/Out Left M16 No FH23510FS19731 12 VDC, 195 W Yes Short In Right/Out Left 7/8"-14 No FH23515 M* FS19731 N/A (open) Yes Short In Right/Out Left (all open) FH23517 FS19730 N/A N/A Short In Right/Out Left 3/8" NPTF No FH23518 M* FS19731 24 VDC, 195 W Yes Short In Right/Out Left M16 No M16 Yes * Metric units - not available in Europe Note: The Diesel Pro 235 can be upgraded to a Diesel Pro 236 by replacing the cover with Fleetguard part number 3973506 S and the filter with Fleetguard part number FS19624. For more information, contact Fleetguard Customer Assistance. Diesel Pro 236 Housing Part Number Filter Element Heater WIF Cover Fuel Flow Fuel In & Fuel Out Port Size Priming Pump FH23600FS19624 N/A N/A Tall In Right/Out Left 7/8"-14 SAE No FH23601FS19624 12 VDC, 195 W N/A Tall In Right/Out Left 7/8"-14 SAE No FH23602FS19624 24 VDC, 195 W N/A Tall In Right/Out Left 7/8"-14 SAE No FH23603FS19728 N/A Yes Tall In Right/Out Left 7/8"-14 SAE No FH23604 M*FS19728 N/A Yes Tall In Right/Out Left M16 No FH23605 M*FS19728 24 VDC, 195 W Yes Tall In Right/Out Left M16 No FH23606 M*FS19728 24 VDC, 195 W Yes Tall In Right/Out Left M16 No FH23607FS19727 N/A Yes Tall In Right/Out Left 7/8"-14 SAE No FH23608 M*FS19727 N/A Yes Tall In Right/Out Left M16 No FH23610FS19728 N/A N/A Tall In Right/Out Left 7/8"-14 SAE No FH23616 M**FS19624 N/A Yes Tall In Right/Out Left M16 No FH23617 M*FS19728 N/A (open) Yes Tall In Right/Out Left (all open) M16 Yes FH23618FS19727 N/A Yes Tall In Right/Out Left 7/8"-14 SAE Yes FH23621 M**FS19624 12 VDC, 195 W Yes Tall In Right/Out Left M16 No FH23622 M**FS19624 24 VDC, 195 W Yes Tall In Right/Out Left M16 No FH23623 M*FS19624 N/A Yes Tall In Right/Out Left M16 Yes FH23624 M*FS19728 12 VDC, 195 W Yes Tall In Right/Out Left M16 No FH23625 M*FS19728 24 VDC, 195 W Yes Tall In Right/Out Left M18 Yes FH23627FS19728 N/A Yes Tall In Right/Out Left 3/8" NPTF No FH23696*** FS19624 N/A Yes Tall In Right/Out Left M16 No * Metric units - available outside North America except Europe ** Metric units available in Europe *** Includes drain valve with hose barb connection
page 13 Ordering Information Diesel Pro 241 Housing Part Number Filter Element Heater WIF Cover Fuel Flow Fuel In & Fuel Out Port Size Priming Pump FH24100 FS20081 N/A Yes Tall In Left/Out Left M16 Yes FH24101 FS20081 N/A Yes Tall In Right/Out Left 7/8"-15 UNF Yes FH24102 FS20081 N/A Yes Tall In Right/Out Left 3/8" NPTF Yes FH24103 FS20081 N/A Yes Tall In Right/Out Left M16 Yes FH24104 FS20081 24 VDC, 195 W Yes Tall In Left/Out Left M16 Yes FH24105 FS20081 24 VDC, 195 W Yes Tall In Right/Out Left M16 Yes FH24106 FS20081 24 VDC, 195 W Yes Tall In Right/Out Left M16 Yes FH24107 FS20081 24 VDC, 195 W Yes Tall In Right/Out Left M18 Yes FH24108 FS20081 120 VDC, 75 W Yes Tall In Right/Out Left 3/8" NPTF Yes FH24110 FS20081 N/A No Tall In Right/Out Left 7/8"-14 UNF No FH24111 FS20081 N/A No Tall In Right/Out Left M16 No FH24112 FS20081 N/A Yes Tall In Right/Out Left 7/8"-14 UNF No FH24113 FS20081 N/A Yes Tall In Right/Out Left M16 No FH24114 FS20081 24 VDC, 195 W Yes Tall In Right/Out Left M16 No Specifications Specification Diesel Pro 235 Diesel Pro 236 Diesel Pro 241 Height Overall 10.75" (273.1 mm) 13.0" (330.2 mm) 13.36" (339.5 mm) Depth Overall 5.8" (147.3 mm) 5.8" (147.3 mm) 5.8" (147.3 mm) Width, max 6.22" (158.0 mm) 6.22" (158.0 mm) 6.22" (158.0 mm) Mount Bracket Centers or Rear Mount Centers 5.25" (133.4 mm) 3.0" (76.2 mm) 5.25" (133.4 mm) 3.0" (76.2 mm) 5.25" (133.4 mm) 3.0" (76.2 mm) Weight (Dry) 5 lbs (2.27 kg) 5 lbs (2.27 kg) 6-7 lbs (3.72-3.17 kg) Fuel Connections (Inlet) 7/8"-14 (M16 x 1.5) 7/8"-14 (M16 x 1.5) 7/8"-14 (M16 x 1.5) Fuel Connection (Outlet) 7/8"-14 (M16 x 1.5) 7/8"-14 (M16 x 1.5) 7/8"-14 (M16 x 1.5) Fuel Capacity (w/o filter) 70.2 fl oz (1995 ml) 70.2 fl oz (1995 ml) 70.2 fl oz (1995 ml) Operation Fuel Flow Rate 60 gal/h (230 L/h) 90 gal/h (341 L/h) 60 gal/h (227 L/h) Recommended Applications Light and Medium Duty Engines Light and Medium Duty Engines Light and Medium Duty Engines Water Trap Capacity 15.2 fl oz (450 ml) 15.2 fl oz (450 ml) 15.2 fl oz (450 ml) Filter Service Clearance Min. 1.5" (38.1 mm) Min. 1.5" (38.1 mm) Min. 3.5" (88.9 mm) Mounting Bracket Cast in Head Cast in Head Cast in Head Electrical Heater Fuel Types Specifications subject to change without notice. 12 VDC, 195 W, 8.5 A ± 0.8 A 24 VDC, 195 W, 4.5 A ± 0.5 A 120 VAC, 75 W, 0.64 A ± 0.06 A 12 VDC, 195 W, 8.5 A ± 0.8 A 24 VDC, 195 W, 4.5 A ± 0.5 A 120 VAC, 75 W, 0.64 A ± 0.06 A Compatible for use with Diesel #1, Diesel #2, Kerosene, Biodiesel up to B20, and JP8 12 VDC, 195 W, 8.5 A ± 0.8 A 24 VDC, 195 W, 4.5 A ± 0.5 A 120 VAC, 75 W, 0.64 A ± 0.06 A
page 14 Dimensions Flow vs. Restriction Diesel Pro 235 11.10 (281.9) 5.71 (145.0) 6.22 (158.0) 5.25 (133.4) All dimensions are in inches (millimeters) Service Height 1.5 (38.1).41 (10.3) (2X ) 2.92 (74.1) 1.54 (39.2) 2.28 (58.0) Differential Pressure (In-Hg) Fl ow (L/hr) 0 100 200 300 400 500 600 3.0 FS19730 2.5 2.0 1.5 1.0 0.5 0.0 0 20 40 60 80 100 120 140 160 Flow (gal/hr) 10.0 8.0 6.0 4.0 2.0 0.0 Differential Pressure (kpa) Diesel Pro 236 Service Height 1.5 (38.1) 2.92 (74.1) 13.1 (332.7) 6.22 (158.0) 5.25 (133.4) 5.71 (145.0) All dimensions are in inches (millimeters).41 (10.3) (2X ) 1.54 (39.2) 2.28 (58.0) Differential Pressure (In-Hg) Fl ow (L/hr) 0 50 100 150 200 250 300 1.4 1.2 1.0 0.8 FS19624 4.0 3.0 0.6 2.0 0.4 0.2 0.0 1.0 0.0 0 10 20 30 40 50 60 70 80 90 Flow (gal/hr) Differential Pressure (kpa) Diesel Pro 241 6.22 [158.0] 5.25 [133.4] Service Height 3.50 [88.9] 2.92 [74.1] 8.00 [203.2] MAX 2.21 (56.0) ø.53 [13.5] (2) holes 5.44 [138.2] 13.12 [333.1] MAX 6.22 (158.0) 5.25 (133.4) All dimensions are in inches (millimeters) ø.41 (10.3) (2X) 1.34 [34.0] 16.03 [407.2] MAX 1.71 [43.4] 2.28 [58.0] Differential Pressure (In-Hg) Fl ow (L/hr) 0 50 100 150 200 250 300 2.1 7.0 FS20081 1.8 6.0 1.5 5.0 1.2 0.9 4.0 3.0 0.6 2.0 0.3 0.0 1.0 0.0 0 15 30 45 60 75 90 105 120 150 Flow (gal/hr) Differential Pressure (kpa)
page 15 Revision Date Description 7 10/10/2017 Added FH241 Series 8 11/1/2017 SP1312 was 3972254 S SP1313 was 3976892 S SP1314 was 3976891 S Heaters 195 W was 250 W and 150 W 3976891 S, 250 W is obsolete 2 VDC, 195 W, 8.5 A ± 0.8 A was 12 VDC, 150 W, 12.5 A ± 1.3 A 24 VDC, 195 W, 4.5 A ± 0.5 A was 24 VDC, 150 W, 6.3 A ± 0.6 A Added Flow vs Restriction graphs Added FH23696 to Ordering Information 9 3/27/2018 Revised heater installation graphics, Fuel Type Biodiesel up to B20 was Biodiesel, Revised Diesel Pro 241 Dimension graphics, Added Priming Pump and Check Valve Service Kits to Parts Lists, Corrected conversion units on performance graphs 10 5/22/2018 FH23625 M thread size M18 was M16 For more information, visit cumminsfiltration.com LT36147 Rev. 9 2018 Cummins Filtration Inc. Printed in the U.S.A.