Davco DIESEL PRO 243 User manual

TABLE OF CONTENTS
Applications, Models, and Options....................................... 1
How it Works ........................................................... 1
“SEEING IS BELIEVING”®............................................... 2
Dimensions and Specifications.......................................... 3
Important Safety Precautions............................................ 4
Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Priming the Fuel System ................................................ 6
Water-in-Fuel (WIF) Sensor Installation .................................. 6
120VAC Overnight Heater Installation.................................... 7
12 or 24VDC Pre-heater Installation...................................... 8
Visual Diagnostics-Air vs. Vapor Bubbles................................. 9
Diagnostic Procedures for Air Leaks ....................................10
Visual Diagnostics with Clear Cover ....................................11
Diagnostic Procedures For Pre-heater/Overnight Heaters ...............12
Filter Change Procedure ...............................................13
Preventative Maintenance .............................................14
Check Valve Service ...................................................15
Service Part Numbers..................................................18
Warranty Policy ........................................................19
Parts Return Policy ....................................................20
2019 ©DAVCO Technology, LLC. Last updated 12-12-2019
FOR UPDATED INFORMATION VISIT WWW.DAVCO.COM
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DIESEL PRO®243 TECHNICAL MANUAL

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DIESEL PRO®243
TECHNICAL MANUAL
F1215 REV H
DIESEL PRO®243 TECHNICAL MANUAL
The DieselPro 243 combines the features of fuel filtration, fuel/water separation
and fuel filter preheating into a single, compact unit. It is intended for any diesel
engine with:
• Flow rates up to 60 GPH
• Biodiesel/Renewable Fuel Compatibility
Applications
• Class 4, 5, & 6 Trucks
• Pickup Trucks
• Refrigeration Units
• School buses
Models and Options
• Base Model-Unheated
• 12VDC, 24VDC Pre-heater or
120VAC Overnight heater
• Water-In-Fuel (WIF) Sensor
Fuel System Diagram
HOW IT WORKS
APPLICATIONS, MODELS, AND OPTIONS
• 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 continues to rise to maintain a fuel path through the clean filter media with low restriction.
• Clean, water-free fuel exits the DieselPro and flows to the engine fuel injection system.
FUEL TANK
ENGINE LIFT PUMP FUEL TO ENGINE
FUEL FROM TANK
FUEL TO TANK
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DIESEL PRO®243
TECHNICAL MANUAL
F1215 REV H
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.
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.
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 main-
taining lowest restriction.
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.
“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. This far exceeds the
performance of cellulose media.
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DIMENSIONS AND SPECIFICATIONS
SPECIFICATIONS
Height, Overall 13.00 inches (330.2 mm)
Depth, Overall 5.80 inches (147.3 mm)
Width, Maximum 6.30 inches (160.0 mm)
Mount Bracket Centers 5.25 inches (133.4 mm)
Weight, Dry 7.7-8.5 lbs.
Recommended Minimum
Service Height
3.5 inches (88.9 mm)
Fuel Flow, Maximum 60 gph
Pre-heater 12VDC 195W or 12VDC 155W
Overnight heater 120VAC 75W
PORT INTERFACE
Fuel In Connection ⅜"-18 NPTF or ½"-14 NPTF
Fuel Out Connection ⅜"-18 NPTF or ½"-14 NPTF
FILTRATION PERFORMANCE AT 60 GPH
Micron Coarse Water
Removal (%)
Emulsified Water
Removal (%)
Dirt Holding
Capacity
(grams)
7 99.6 98.9 118
0.0
0.5
1.0
1.5
2.0
2.5
0 25 50 75 125 150 175 200 225100
Restriction vs. Flow
Flow (gph)
Differential Pressure (in-Hg)
DIESEL PRO®243 TECHNICAL MANUAL
5.250
[133.4]
3.50
[88.9]
RECOMMENDED
MIN. SERVICE HEIGHT
6.22
[158.0]
13.00
[330.2]
MAX
5.80
[147.3]
MAX.
MOUNTING HOLE DISTANCE: 5.250 33.4
MOUNTING HOLE OPENINGS: .400 .408. 10.1610.36
FRONTLEFT RIGHTBOTTOM
All dimensions are in inches [millimeters]

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DIESEL PRO®243 TECHNICAL MANUAL
IMPORTANT SAFETY PRECAUTIONS
General Safety Precautions
• FOR USE WITH DIESEL FUEL ONLY
• To avoid serious injury or death, follow the safety information in this document.
• Keep this manual. If you need to replace the manual, call customer service at 800-328-2611
or visit www.davco.com for a replacement.
• Refer to appropriate regulations for environmental and workplace safety rules.
WARNING: 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 temperature
before replacing the fuel filter or performing service operations which could result in spillage of fuel from the fuel
system.
• 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.
• Do not energize the pre-heater outside of the Diesel Pro. It can become very hot.
Government Regulations
• Engine fluids (oil, fuel, and coolant) may be a hazard to human health and the environment. Handle all fluids and other
contaminated materials (such as filters and rags) in accordance with applicable regulations. Recycle or dispose of
engine fluids, filters, and other contaminated materials according to applicable regulations.

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DIESEL PRO®243
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Installation Location
The DieselPro must be installed between the fuel tank and
the fuel transfer pump. In some cases, the DieselPro can
be used as the only fuel filter in the system. This is generally
dependent on the engine model year. Consult the engine
manufacturer for their recommendation.
• Do not install the DieselPro directly on the engine.
• Mount vertically with the cover and element pointing up.
• Make sure there is enough top and side clearance for the
cover to be conveniently removed for filter replacement
(3.5" minimum).
• 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.
EThe ignition key must be in the off position. To avoid
unintentional engine startup, use a lockout key and/or
signage to alert personnel that work is being per-
formed. Chock the wheels.
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. Drain and remove the primary fuel filter element assem-
bly, sedimenter, and/or water separator. Dispose of it in
an environmentally responsible manner.
3. Mount the DieselPro in the desired location using ⅜"
Grade 8 bolts.
Painting Precautions
The collar/cover joint and threads are designed to be free
of paint in order to function properly. The cover and collar
assembly must be completely masked off if the Diesel Pro is
to be painted.
Fuel Line Routing
To minimize fuel system restriction, observe the following
guidelines when plumbing the fuel system:
• Keep the fuel line routing as smooth as possible with no
low-hanging loops which can trap water.
• Use 90° elbows only when necessary.
• If the fuel hoses are cut to length on site, be sure that 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.
• To avoid damaging the aluminum DieselPro body, do not
overtighten fuel lines or fuel line fittings.
1. Route the fuel supply line from the pick up on the fuel
tank to the DieselPro inlet (labeled “FUEL IN” on the
housing)
2. Route the fuel outlet line from the DieselPro outlet
(labeled “FUEL OUT” on the housing) to the inlet of the
fuel pump.
The inlet and outlet fittings can be moved from side to side
depending on the applications needs. (Example : FUEL IN
right and FUEL OUT right use only one inlet and one outlet
port per installation.
RIGHT SIDE
LEFT SIDE
FUEL IN
FUEL OUT
INSTALLATION INSTRUCTIONS
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DIESEL PRO®243 TECHNICAL MANUAL
1. Remove the vent cap. Open the drain valve. Drain the
DieselPro completely. Close the drain valve. The fuel can
be reused after the installation.
2. Remove the WIF or the plug.
3. Install the WIF into the WIF port. Torque to 45-60 in.-lb.
4. Prime the Diesel Pro (see page 6) and check for leaks. WIF PORT
1. Ensure that the drain valve at the base of the Diesel Pro is
closed.
2. Remove the vent cap from the top of the clear cover.
Fill the Fuel Pro with clean fuel. Install the vent cap and
tighten it by hand until it clicks.
3. Start the engine. When the lubrication system reaches its
normal operating pressure increase the engine RPM to
high idle for one to two minutes.
4. After the air is purged and while the engine is at idle,
loosen the vent cap and let the fuel level drop to just
above the collar, then tighten the vent cap by hand until it
clicks.
It is normal for the fuel level to vary after the initial start-up
and during engine operation. Filter performance is not
affected.
PRIMING THE FUEL SYSTEM
WATERINFUEL WIF SENSOR INSTALLATION

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DIESEL PRO®243 TECHNICAL MANUAL
120VAC OVERNIGHT HEATER INSTALLATION
The DieselPro can have either a 12/24VDC Pre-heater or an
120VAC Overnight Heater installed. It is not designed for two
heaters to be installed into the housing.
1. Remove the vent cap. Open the drain valve and drain the
DieselPro completely. Close the drain valve. The fuel can
be reused after the installation.
2. Remove the plug from either heater port. Use the port
that provides the easiest access (see Figures 1 and 2).
RIGHT SIDE
LEFT SIDE
HEATER PORTS
Figure 1
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Figure 2
3. Install the bushing into the heater port. Torque to 15-30
ft-lb (see Figure 3).
The bushing utilizes an o-ring seal and does not require
sealant.
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Figure 3
4. Apply liquid or paste type thread sealant to the threads of
the pre-heater and install it into the bushing (see Figure
4). Torque to 25-40 ft-lb.
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Figure 4
5. Connect the cord to the overnight heater. Connect the
other end of the harness to the engine block heater.
Connect the cord to a 120VAC output location on the
truck (usually located below the driver’s door).
6. Prime the Diesel Pro (see page 6) and check for leaks.

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TECHNICAL MANUAL
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DIESEL PRO®243 TECHNICAL MANUAL
The DieselPro can have either a 12/24 VDC Pre-heater or an
120VAC Overnight Heater installed. It is not designed for two
heaters to be installed into the housing.
RIGHT SIDELEFT SIDE
HEATER
PORTS
1. Remove the vent cap. Open the drain valve and drain the
DieselPro completely. Close the drain valve. The fuel can
be reused after the installation.
2. Remove the plug or pre-heater from either heater port.
Use the port that provides the easiest access.
3. Apply liquid or paste type thread sealant to the pre-heater
threads and install the heater. Torque to 25-40 ft-lbs.
4. Prime the Diesel Pro (see page 6) and check for leaks.
5. Connect the chassis harness to the pre-heater harness.
6. Connect the power lead to the fused accessory side
of the ignition switch. The fuse rating depends on the
pre-heater installed.
Approved fuse ratings
The voltage and wattage ratings are stamped on the hex of
the pre-heater for identification purposes.
• 12VDC System:
- 20 amp fuse for a 155W PTC pre-heater
- 25 amp fuse for a 195W PTC pre-heater
• 24VDC System:
- 15 amp fuse for a 195W PTC pre-heater
• If the keyed circuit will not handle the required amperage
for the pre-heater, install a relay as shown below.
85
30/51
87
86
12/24VDC
OPTIONAL
RELAY
+ -
Heater
Pre-heater Fuse
Harness
Connector
Ignition
Circuit
Fuse
Ignition Switch
87A
87
86
85
30/51
Pre-heater Wiring with Relay
12 OR 24VDC PREHEATER INSTALLATION

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VISUAL DIAGNOSTICSAIR VS. VAPOR BUBBLES
Air Bubbles
Air bubbles are caused by any air leak on the vacuum (suc-
tion) side of the fuel system from the fuel tank pick-up to and
including the lift pump (see Figure 1).
If there is an air leak in the fuel system, air bubbles will be
present in the clear cover of the DieselPro. Follow test
procedures outlined in “Diagnostic Procedures for Air Leaks”
for air leak diagnostics. If there are no bubbles present in
the DieselPro cover and the engine continues to run rough,
lopes or has a loss of power, there may be an air leak between
the DieselPro outlet port and lift pump inlet. This type of air
bubble can be seen if a sight tube is installed at the lift pump
inlet. Air bubbles may also be visible in the fuel return (spill)
hose out of the fuel gallery. These leaks are easily eliminated
by checking and torquing the fuel fittings in the area of the
leak.
TEST 1: A quick procedure to determine if the air leak
is between the fuel tank and the DieselPro is to remove
the DieselPro inlet hose and route a new hose from the
DieselPro inlet into a container of fuel or the fuel tank fill cap
opening. Start the engine and check for bubbles.
If there are no air leak symptoms, but bubbles are present in a
sight tube at the fuel lift pump inlet, they are most likely vapor
bubbles.
Vapor Bubbles
All diesel fuel has some level of entrained air caused by the
natural splashing that occurs in the fuel tank during normal
vehicle or equipment operation. Vapor bubbles develop in
the DieselPro because the pressure inside the DieselPro is
lower than the atmospheric pressure in the fuel tank. Vapor
bubbles can vary from champagne size up to ¼" in diameter.
They may increase in size or volume as engine RPM increas-
es. The lower pressure draws the entrained air/vapor out of
the fuel and these bubbles will be visible as the fuel exits the
DieselPro (See Figure 2). As the fuel enters the lift pump, it
is pressurized and the bubbles are compressed back into the
fuel. There will be no bubbles on the fuel return side of the
system. These vapor bubbles will not affect the performance
of the engine.
TEST 2: An easy way to determine the difference between
vapor and air bubbles is by temporarily removing the filter
element from the DieselPro. Fill the cover with clean diesel
fuel, replace the vent cap and re-run the outlet fitting sight
glass test. If there are no bubbles visible in the sight glass,
then the bubbles that were previously visible were vapor
bubbles. If bubbles are still present then they are air. If air
bubbles still exist, re-run the test in TEST 1to eliminate the
chassis plumbing as a variable.
There is no troubleshooting or repair procedure required
for vapor bubbles. Vapor bubbles do not cause perfor-
mance issues and will not be present after the lift pump.
Figure 1 Figure 2
DIESEL PRO®243 TECHNICAL MANUAL
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.
FUEL RETURN
ENGINE
LIFT PUMP
FUEL
TANK
LIFT PUMP
FUEL RETURN
ENGINE
LIFT PUMP
FUEL
TANK
LIFT PUMP
AIR BUBBLES VAPOR BUBBLES

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DIAGNOSTIC PROCEDURES FOR AIR LEAKS
Every DieselPro is factory tested for leaks and is identified
with a traceable number prior to shipment. 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 or paste type thread sealant.
All suction side fuel filters experience bubbles. It is normal to
see champagne size bubbles in the DieselPro cover, at the
DieselPro outlet or at the lift pump.
IN ORDER TO RETURN A FUELPRO FOR EVALUATION,
THE FOLLOWING PROCEDURESTESTS MUST BE
COMPLETED BEFORE REQUESTING A DAVCO RGA
RETURN GOODS AUTHORIZATION NUMBER.
I. Air bubbles will be visible in the clear cover of the
DieselPro if the leak originates between the fuel tank and
the DieselPro. The following is a quick test to isolate the
air leak source.
A. Remove the DieselPro inlet hose.
1. Install a jumper hose from the DieselPro to the
fuel tank (through the fill cap) or to a container of
fuel.
2. Start the engine. If this eliminates the air bub-
bles, the air source is at the fuel tank fittings or
hose connections.
3. Tighten all fittings and connectors. Retest.
a. If air bubbles persist, the air source is on the
DieselPro side of the system:
i. Tighten all fittings on the DieselPro.
ii. Loosen the collar until it spins freely.
Apply downward pressure on the top of
the cover and rotate the collar until con-
tact. Use a DAVCO wrench (if necessary)
to tighten the collar three additional ribs.
b. If the drain valve is suspected, install a plug
in place of the drain valve (for test purposes
only).
4. If air bubbles persist, test as follows:
a. Remove the DieselPro from the chassis.
Plug the fuel outlet port. Do not remove filter,
cover/collar, vent cap, drain valve and/or
check valve. If the DieselPro is equipped with
a pre-heater, do not remove the pre-heater.
b. Apply 15 PSI of air pressure at the fuel inlet.
Immerse the DieselPro in a tank of water and
look for air bubbles.
c. Correct the source of the air leak and retest.
II. Bubbles Not Visible: 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 tting,
vent cap o-ring, the lift pump inlet connection, or the fuel
hose⁄connections to the lift pump. Inspect and tighten
ttings as needed.
III. Excessive Restriction: If the fuel level is at the top of the
lter, replace the fuel lter. The DieselPro will not cause
excess system restriction if the fuel level is below the top
of the lter. The only exception is if the grommet is not
installed in the bottom of the lter element.
IV. Loss of Prime: When air is introduced into the fuel
system, (i.e. draining water from the DieselPro or when
replacing the fuel lter) 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 every DieselPro.
V. To test for proper check valve operation, put a drain pan
under the DieselPro, remove the fuel inlet hose and open
the vent cap. Fuel should not ow out of the DieselPro,
although slight seepage of fuel is normal.
If fuel flows out of the unit, follow the check valve testing
procedures on page 15.
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VISUAL DIAGNOSTICS WITH CLEAR COVER
DIESEL PRO®243 TECHNICAL MANUAL
Fuel level is not at the top of the fuel filter.
ÎNormal-Do not change the filter.
Fuel level is at the top of the filter. Low power.
ÎChange the filter at the first available opportunity.
Water is noticed in the cover.
ÎDrain the water.
Bubbles are seen flowing in with the fuel.
ÎCheck all fittings and lines from the fuel tank to the DieselPro. Check the cover and vent cap o-rings.
Fuel drains back to the fuel tank when changing the fuel filter or draining separator.
ÎRemove the check valve assembly. Clean or replace and retest. Check air leaks in the fuel system.
There is a power complaint and the fuel level is below the collar.
ÎCheck for a missing grommet at the lower end of the filter or missing/broken spring at top of filter.
Fuel level is at the top of the filter and appears to be full of wax.
ÎChange the filter. Run the engine for a minimum of 25 minutes at idle. Do not run at full RPM.

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DIESEL PRO®243 TECHNICAL MANUAL
DIAGNOSTIC PROCEDURES FOR PREHEATEROVERNIGHT HEATERS
Equipment Needed
• A precision low resistance ohm meter capable of
measuring with accuracy to two decimal places.
• Current flow meter (clamp-on type for DC current).
EDO NOT USE a test light that has a wire probe for any
of these tests. If the wiring insulation is punctured,
moisture and road salt can penetrate into the wires
creating a corrosion issue and potential failure.
CAUTION!
EDo not energize the pre-heater outside of the
DieselPro. It can become very hot.
12VDC/24VDC PTC Pre-heater Test Procedure
There are various configurations of pre-heaters available,
including both 12VDC and 24VDC pre-heaters.
The voltage and wattage ratings are stamped on the hex of
the pre-heater for identification purposes.
1. Disconnect the harness from the pre-heater.
2. Connect the ohm meter leads to the pins of the pre-heat-
er. Use the following to determine whether the pre-heater
resistance value is in the acceptable range.
PTC Pre-heater Watts Resistance Range (ohms)
12VDC 195W 0.4 to 0.6 @ 77°F (25°C)
24VDC 195W 2.0 to 3.0 @ 77°F (25°C)
12VDC 155W 0.95 to 1.2 @ 77°F (25°C)
120VAC Overnight Heater Test Procedure
1. Disconnect the cord from the overnight heater.
2. Connect the ohm meter leads to the pins of the overnight
heater. Use the following to determine whether the over-
night heater resistance value is in the acceptable range.
Overnight Heater Watts Resistance Range (ohms)
120VAC 75W 173 to 203 @ 77°F (25°C)

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F1215 REV H
FILTER CHANGE PROCEDURE
Change the filter when the fuel reaches the top of the
“CHANGE FILTER” lettering on the cover.
For filter selection visit www.davco.com for the correct filter
for your application or call DAVCO Customer Service at
800-328-2611.
FILTER PART NUMBERS
7 micron EleMax Filter, Fleetguard FS19624
10 micron EleMax Filter, Fleetguard FS19727
25 micron EleMax Filter, Fleetguard FS19728
1. Remove the vent cap and open the drain valve to drain
the fuel below the collar level. Close the drain valve.
2. Remove the collar using the DAVCO collar wrench (P/N
242007DAV). Remove the clear cover.
3. Remove the filter and seals. Dispose of the filter and the
seals properly.
4. Using a clean shop rag, clean the cover, collar, vent cap
and threads on the DieselPro body. Do not use harsh
chemicals to clean the clear cover.
5. Install the new filter and seals.
6. Install the clear cover and collar.
7. Apply downward pressure on the top of the cover and
rotate the collar until contact.
8. Use a DAVCO wrench (if necessary) to tighten the collar
three additional ribs (..
12
3
9. Prime the Diesel Pro (see page 6) and check for leaks.
It is normal for the fuel level to vary after the initial start-up
and during engine operation. Filter performance is not
affected.
DIESEL PRO®243 TECHNICAL MANUAL

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DIESEL PRO®243 TECHNICAL MANUAL
PREVENTATIVE MAINTENANCE
Preventative Maintenance
Environmental Concerns and Seasonal Maintenance
• Steam clean the DieselPro with fresh water regularly to keep corrosive salt or dirt from building up on the housing, cover
and collar.
• Extreme winter or salt corrosion environments may require lubrication of the collar with anti-seize lubricant every 180 days.
Weekly water drains
1. Turn off the engine and remove the vent cap.
2. Place a suitable container under the DieselPro and open the drain valve.
3. Collected 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.
4. Install the vent cap and tighten it by hand until it clicks.
5. Start the engine and raise the RPM for one minute to purge the air from the system.
During each filter change
• Change the o-rings on the cover and vent cap (included with the service filter kit).
Annual inspection
• Inspect all electrical connections and housing for corrosion.
• Inspect all fuel fittings for leaks.
• Inspect the DieselPro for damage or signs of leaks.

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DIESEL PRO®243
TECHNICAL MANUAL
F1215 REV H
DIESEL PRO®243 TECHNICAL MANUAL
To test for proper check valve operation, place a drain pan
under the DieselPro, remove the fuel inlet hose and open the
vent cap. Fuel should not flow out of the DieselPro, although
slight seepage of fuel is normal. If fuel flows out of the
DieselPro fuel inlet:
1. Remove the vent cap. Open the drain valve. Drain the
DieselPro completely. Close the drain valve. The fuel can
be reused after the installation.
2. Remove the collar, cover and filter.
3. Remove the checkvalve assembly.
4. Clean and inspect the checkvalve. If the check valve
appears damaged, order P/N 240033DAV.
5. Install the checkvalve into the DieselPro. Torque to 5-7
ft-lb. Apply liquid or paste type thread sealant to the fuel
inlet fitting and reconnect the fuel inlet hose.
6. Install the filter and seals.
7. Install the clear cover and collar. Apply downward
pressure on the top of the cover and rotate the collar until
contact.
8. Use a DAVCO wrench (if necessary) to tighten the collar
three additional ribs (..
12
3
9. Prime the Diesel Pro (see page 6) and check for leaks.
It is normal for the fuel level to vary after the initial start-up
and during engine operation. Filter performance is not
affected.
CHECK VALVE SERVICE

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DAVCO Technology, LLC www.davco.com800-328-26111600 Woodland Drive, Saline, MI 48176-1629
DIESEL PRO®243
TECHNICAL MANUAL
F1215 REV H
SERVICE PARTS AND KITS
A 240002SDAV Collar
B 240023DAV Vent Cap Service Kit (vent cap and o-ring)
C 243013SDAV Cover, Collar, Spring, Vent Cap and Vent Cap
O-ring (Collar o-ring not included)
243011DAV (not
shown)
Cover Sub-assembly (Hino Only)
D 243017DAV Cover with Red Stripe, Collar, Spring, Vent Cap
and Vent Cap O-ring (Collar o-ring not included)
D
E 232009DAV O-ring Service Kit (Vent Cap/Collar)
F 380056DAV Spring
G240033DAV Check Valve
H 102821SDAV Plug ⅞"-14
I 101332DAV Drain Valve
J 102825DAV Bushing for Overnight Heater (required for
installation of 120VAC Overnight heater if was
not previously installed)
⅞"-14 to ½"-14 NPTF
K 102820SDAV Bushing for Overnight Heater (required for
installation of 120VAC Overnight heater if was
not previously installed)
⅞"-14 to ⅜"-18 NPTF
L 232007DAV Collar Wrench
M 103604DAV Combination Drain Kit
(Includes drain, dust cap and plug, for use on
units with cover with red stripe. Part number
for unit contains an "E". Replaces ESOC fitting
102844, except on Freightliner Trucks.)
Housing is not a
service part.
H
H
I
G
F
C
A
E
B
J
K
K
FILTERS* FOR DIESELPRO 243
FS19624 7 Micron EleMax Filter, Fleetguard
FS19727 10 Micron EleMax Filter, Fleetguard
FS19728 25 Micron EleMax Filter, Fleetguard
*For filter selection visit www.davco.com for the correct filter for your application
or call DAVCO Customer Service at 800-328-2611.
Contact DAVCO Customer Service for
OEM Part Numbers.
L5"
M
DIESEL PRO®243 TECHNICAL MANUAL
SERVICE PART NUMBERS

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DIESEL PRO®243
TECHNICAL MANUAL
F1215 REV H
PREHEATER PARTS
103525DAV 12VDC 195W PTC Pre-heater, Weather Pack Connector, ⅞"-14
UNF Threads, Harness Length 7.50"
103526DAV 12VDC 195W PTC Pre-heater, Metri-Pack Connector, ⅞"-14
UNF Threads, Harness Length 7.50"
103527DAV 12VC 195W PTC Pre-heater, Yazaki Connector, ⅞"-14 UNF
Threads, Harness Length 30.41" (Hino)
103540DAV 24VDC 195W PTC Pre-heater, Male Weather Pack Connector,
⅞"-14 UNF Threads, Harness Length 7.50"
103552DAV 12VDC 195W PTC Pre-heater, Metri-Pack Connector, ⅞"-14
UNF Threads, Harness Length 7.50"
103593DAV 12VDC 155W PTC Pre-heater, Metri-Pack Connector, ⅞"-14
UNF Threads, Harness Length 17" (Freightliner)
103595DAV 12VDC 155W PTC Pre-heater, Metri-Pack Connector, ⅞"-14
UNF Threads, Harness Length 7.50" (Freightliner)
103596DAV 12VDC 155W PTC Pre-heater, Metri-Pack Connector, ⅞"-14
UNF Threads, Harness Length 7.50" (Freightliner)
102376DAV Pre-heater Chassis Harness, Metri-Pack Connector
102220DAV Pre-heater Chassis Harness, Weather Pack Connector
DIESEL PRO®243 TECHNICAL MANUAL
SERVICE PART NUMBERS

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DIESEL PRO®243
TECHNICAL MANUAL
F1215 REV H
OVERNIGHT HEATER PARTS
102145DAV 120VAC 75W Overnight Heater, ½"-14 Threads (Adapter P/N
102825DAV required for installation of a 120VAC overnight
heater if not was previously installed)
102015DAV 120VAC “Y” Cord
101868DAV 120VAC Overnight Heater Straight Cord
WATERINFUEL WIF SENSOR PARTS
102512DAV Two Pin WIF, Deutsch Connector (gray), ½"-20 UNF Threads,
Harness Length 3.36.
102521DAV Two Pin WIF, Deutsch Connector (black), ½"-20 UNF Threads,
Harness Length 3.36"
102483DAV Two Pin WIF, Metri-Pack Connector, ½"-20 UNF Threads,
Harness Length 6"
102770DAV Two Pin WIF, Metri-Pack Connector, ½"-20 UNF Threads,
Harness Length 6.50" (Freightliner)
103111DAV Two Pin WIF, Tyco/AMP Connector, ½"-20 UNF Threads,
Harness Length 3.25" (Paccar)
103153DAV Two Pin WIF, Yazaki Connector, ½"-20 UNF Threads, Harness
Length 20.94" (Hino)
102600DAV Two Pin WIF Wiring Harness (Used with 102512 and
102521DAV) Deutsch Connector
DIESEL PRO®243 TECHNICAL MANUAL
SERVICE PART NUMBERS