Fass T D10 125G User manual

INSTALLATION MANUAL
APPLICATION:
T D10 125G (125GPH @ 45psi)
Cummins 5.9L 12Valve
*with P7100 Injection Pump*
Standard Pickup Truck
1994-1998
**Note: Cab and Chassis
may require modications**

Serial #
FASS Recommended Application
T D10 125G Cummins 1994-1998 with stock - extreme horsepower modifications
Note: Because of the higher fuel flow these systems have to offer, you may encounter
problems 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!
Cab and Chassis may require modifications
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.

INSTALLATION MANUAL
Follow these steps to ensure a simple installation of your new
FASS TITANIUM FUEL SYSTEM
1. Inventory the package components completely. Notify the place of purchase imme-
diately of any parts missing or damaged.
2. Read the installation manual completely before attempting installation. Under-
stand how the system operates and read installation recommendations before be-
ginning installation.
3. The installation recommendations contained herein are guidelines. Its important to
understand your vehicles accessories and limitations. Use good judgment and take
in to 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. We are not responsible for any installation mis-
takes.

Titanium Series
125 gph
45 PSI (Approximately)
Instal-
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
A fuel pressure gauge is highly recommended to identify fuel filter life and to prevent engine damage!
“H”
Coolant Heater
‘R’
Fuel Return to Tank
“E”
To Engine
Serial Number Location
‘G’
Fuel Pressure
‘T’
Fuel Inlet
Electric Heater
Port
2nd
Electric Heater Port

WH-1005
MP-9031
PBR-2001
FL-1002 x15’
FL-1056 x3’
PFB-2002
Contents
FL-1058 x3’

*WE-1001*
46044
Mounting Package Contents
PL-2003
HC-4001
10-300
Ring Terminal
DIPF-1004 BT-14x03
CP-1003
HB-14516
PB-14316
PL-1005 10-302
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
PL-1010
PL-1058
BHF-1002
ST-1005Px16”
OR-223
BHN-1001
LW-1001
46260
PL-1004

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 46044 and
the WE-1001.
B. 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
46044 lead through the fire wall using existing grommet.

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-1005 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.
NOTE: Before installing fittings make sure to inspect for burs or flare imperfections.
When cutting fuel line make sure to blow out line to keep debris from moving forward.

C. Disconnect the factory suction and return line. The factory lines are re-
moved by pressing in on the two tabs located in the connecting harness.
These tabs are opposite of each other.
D. Disconnect the factory electrical harness located between the suction
and return lines on top of the fuel tank.
E. With the fuel tank empty of fuel, remove it from the vehicle.
F. Clean the fuel module area then remove the lock ring on the top of the
fuel tank.
G. Once the lock ring is removed, carefully remove pick up module from
fuel tank while making note of fuel level arm.
H. Assemble the BHF-1002 with the PL-1010 in port “S” & the PL-1004
in the “R” port using thread tape. Torque to 40 ft./lbs. Push the ST-
1005P onto the barb portion of the BHF-1002. Insert O-ring into
groove.
B. Remove the filler neck and overflow tubes from the truck by loosening
the clamps at both ends.
Step 2: Prepare suction & Return lines
A. Before tank is removed or moved, identify ALL areas of clearance be-
tween the tank and the truck’s bed for the best location to install the
BHF assembly. With proper clearance, you want to install it as close to
the Fuel sending unit as possible.
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.

M. With proper length being obtained, place the assembly into the drilled
hole securing the assembly using the lock washer & nut. Loctite may be
applied to the threads of the BHF-1002 for added insurance.
J. Drill a 1 3/8” hole, catching all debris. De-bur hole and remove any
missed debris in the fuel tank.
K. VERY IMPORTANT: Support fuel tank on both ends allowing the nat-
ural formation of the tank to take place. Failure to perform this step can
and will create an issue with less usable fuel!
L. Place the bulk head assembly into the drilled hole, take measurements so
the bottom of the suction tube is only 1/8” (no more than 2 quarters
stacked) from the bottom of the fuel tank. Using a razor knife make mul-
tiple cuts to insure proper length, it is easy to shave the suction tube with
the razor. It is more efficient to cut the tube too long and then correct
to proper length than it would be to cut too short.
I. Before drilling marked location, clean area of debris. Using the photo,
double check area selected for any interference including the fuel level
arm.
N. Carefully reinstall install pick up module making sure the leveling arm is
not obstructed by the suction tube. Reinstall factory lock ring. Reconnect
factory wire harness and factory fuel lines
Step 2: Prepare suction & Return lines

NOTE
ATTENTION: While installing fittings into Titanium pump
DO NOT Apply side pressure to draw
tube of pump
Improper
Proper

Step 3: Mount Fuel System
B. For fitting purposes. Secure PBR-2001 to pump assembly lightly with (3) 1/4”-20x1 3/4 bolts and (3)
WA-1001D. This will assembly will be used in future steps for correct fitting of brackets. (Note:
Bracket maybe flipped to accommodate your application.)
A. Using thread tape, install the 10-300 into “E” and the 10-302 into the “T” port (on opposite end).
Torque to 40 lb./ft.² Note: Do Not Put Thread Tape on Flare of Fitting ***The use of
thread sealant is not recommended***

Step 3: Mount Fuel System
F. Connect factory plug into the FASS harness. Connect female plug of the FASS harness into pump.
Turn key to “on”. With pump operating (you may have to bump the starter), turn pump over, liberally
spray WD-40 (or equivalent) into water separator nipple lubricating Gerotor.
E. Position the PBR-2001 to the PFB-2002 pump assembly at the mounting location and check for fit.
Once location is established mark location for mounting in next step.
D. Secure PFB-2002 and RS-2001 with bed bolt in previous step.
C. Unbolt driver side front bed bolt from bed retain bolt for future use. Align RS-2001 with PFB-2002.
.

H. Once secure use (3) 1 3/4 bolts and (3) WA-1001D spacers to mount the pump to the bracket.
Step 3: Mount Fuel System
G. Assemble the FASS pump bracket PBR-2001 using the RS-2002 spacer between PFB-2002 and PBR-
2001 bracket with 4-3/8 bolts, nuts, and washers. Note: Torque bolts not flange nut.

Step 3: Mount Fuel System
I. Apply motor oil to gasket located on filters. Attach to system and
hand tighten.
Fuel Filter –Install FF-3003 on
side of pump with draw tube in
the middle of the filter nipple.
Water Separator Filter –Install FS-1001 on water separator
nipple without the draw tube. Make sure to insert O-Ring
provided on nipple.

Step 4: Install Fuel Line
A. Route suction line from the suction tube assy. to port ‘T’ on the
FASS system. . Cut FL-1058 to needed length and insert PL-1058
using oil. Attach to 10-302 in ‘T’ port. Torque to 18 ft./lbs.
C. Connect remaining fuel line to the 10-300 in ‘E’ port of the FASS
system using a PL-1005. Use oil. Route this line up to the P7100 In-
jection pump. Do not cut at this time.
B. Route fuel line from the R’ port from the bulkhead to the ‘R’ port
on the FASS system with a gentle bend. Cut and insert PL-1005 fit-
ting to the hose. Use oil. Attach to 10-300 in ‘R’ port. Torque to 18
ft./lbs.
Caution: Do not use sealant on AN fittings. Only use sealant on threads going into the FASS pump.
D. Disconnect factory fuel line from inlet side of the injection pump.
Install the DIPF-1004 into this port.
E. Insert the PL-2003 fitting into the fuel line. Remember to use oil.
Connect the PL-2003 to the DIPF-1004. Torque to 18 ft./lbs.
F. The return line from the injectors must be T’d into the return line of
the injection pump. Assemble the T-fitting with 2 HB-14516 and the
CP-1003 compression fitting/ PB-14316 bushing using thread tape.
Remove the rubber hoses attached to the Injector Pump Return line
and Injector Return lines. Reuse clamps. Install FL-1056 fuel line
from steel inj. return line to the T fitting, secure with HC-4001
clamp provided in kit and factory clamp. Install the rest of the fuel
line from the T fitting to the factory steel line at the frame. Cut In-
jector Return line (measure twice, cut once), slip on compression
nut, ferrule; hold line tight to T fitting and tighten nut to 18 ft./lbs.
Secure hoses.
Note: Secure all fuel lines with cable ties. Cable ties are an economical way to prevent the
possibility of problems occurring!
NOTE: Hose clamps are not recommended for push lock fittings.
They will hold up to 300psi! Use oil on fittings and inside fuel line
when installing Push-Lok fittings

Note: The Red Plastic Plugs located in the “H” ports can stay in place fuel will not flow
through these ports. Coolant can be plumbed into these ports to heat the fuel in the Winter
months.
******The factory suction line can be capped off or removed from the truck. The openings on
the filter and tank will need to be capped off to keep debris from getting into lines or canis-
ter.**********
To assist with priming your FASS pump crack the FF-3003. Put power to the FASS pump to acti-
vate the pump. When the tone of the pump changes you can tighten up the fuel filter.
Step 5: Review Installation

Step 5: Review Installation
 Blow out any open lines/cover any open ports
 Bolts and fasteners properly tightened?
 Electrical harness and fuel lines secured and properly tightened? Reconnect the battery.
 Has the system been primed?
1. Turn key to the ignition position, turning on the FASS pump for 15 sec..
2. Crank engine and allow to run for at least 1 minute.



Check for leaks.
Start the engine
Recheck all fluid and filter connections for leaks
Note: O-Ring must be put back on suction side of pump.
Failure to do so can result in priming issues, cavitation, or
pressure loses.

Filter Cross References
Fuel Filter (Micron Rang) Water Separator (Micron Rang)
Thread Size (1-14) Thread Size (1-14)
Baldwin BF7633 (2M) Baldwin BF 1258 (10M)
Carquest 86528 (2M) Baldwin BF1214
CAT 1P2299 (6M) Baldwin BF7546 (10M)
CAT 1R0750 (2M) Donaldson P558000 (20M)
Donaldson P551025(4M) Donaldson P551000 (10M)
Donaldson P551311 (3M) Donaldson P551001(10M)
Donaldson P551313 (3M) Fleetguard FS1282 (14M)
Donaldson P553203(3M) Fleetguard FS-1000 (10M)
Donaldson P557440 (6M) Fleetguard FS-1001 (10M)
Fleetguard FF5320(2M) Fleetguard FS-1009(14M)
Fram P8334 (2M) Fleetguard FS-1212(14M)
Hasngs FF1079 (2M) LuberFiner LFF8011
Wix 33352 (6M) LuberFiner LFF8000
Wix 33528 (2M) Motorcra FD818 (14M)
Wix 33674 (2M) Wix 33405(14M)
Wix 33522 (10M)
(Currently in use)
Fuel (FWS-3003)
Water (FS-1001)