DAVCO Fuel Pro® 382 and 482

sd mm 47.02.002

Note: In the event of an emergency, when the filter needs replacement but a DAVCO filter is not available, a temporary filter can be used; see Chapter 24 of the Driver's Manual for instructions.

Warning: Fluid circulated through the fuel/water separator to heat the fuel may be diesel fuel returned from the engine, or engine coolant. Drain the fuel/water separator only when the engine and fluids have cooled. Draining it when the engine is hot could cause severe personal injury due to scalding.

If returning fuel is released into the atmosphere, its vapors can ignite in the presence of any ignition source. Do not expose the fuel to, or work with the fuel system near, open flame or intense heat. To do so could cause fire, possibly resulting in serious personal injury or property damage.

The filter element should be changed only when the fuel level has reached the top of the filter element. There is no significant restriction to fuel flow until the element is completely clogged.

  1. Shut down the engine, apply the parking brake, and chock the tires.
  2. Check the fuel level in the fuel filter. Replace the fuel/water separator element only when the filter element is completely covered. If the fuel level has reached the top of the filter element, follow the procedure below to replace the element.
  3. Put a clean receptacle under the fuel/water separator and attach a piece of hose to the drain valve, to direct fuel into the receptacle.
    The drain valve has a 1/2-inch (12.7-mm) pipe; use a hose with a 1/2-inch pipe thread to fit correctly.
  4. Remove the vent cap (Fig., Item 10) and open the drain valve (Fig., Item 1) to drain the fuel completely, then close the drain valve.

    1. Drain Valve

    2. Bottom Plate Assembly

    3. Bottom Plate O-Ring

    4. Lower Housing

    5. Cover O-Ring

    6. Filter Element

    7. Spring

    8. Clear Cover

    9. Vent Cap O-Ring

    10. Vent Cap

    11. Collar

    12. Grommet

    13. Inlet Port/Check Valve

    14. Heat Exchanger

    Fig. 1, DAVCO Fuel Pro 382

  5. Using a DAVCO Collar Wrench (Fig.), remove the clear cover and collar.

    Fig. 2, DAVCO Collar Wrench

    6. Note: Broken vent cap and collar warranty claims will not be accepted if any tool other than a DAVCO Collar Wrench is used for removal. During installation, the vent cap is to be hand-tightened only , not tightened with a wrench. Use part number 482017 on Fuel Pro 482 units; part number 380134 on Fuel Pro 382 units.

  6. Remove the filter, cover O-ring, and vent cap O-ring. Dispose of them in an environmentally acceptable manner. See Fig. or Fig..

    1. Inlet Port/Check Valve

    2. Lower Housing

    3. Bypass Valve

    4. Filter Element

    5. Spring

    6. Clear Cover O-Ring

    7. Clear Cover

    8. Vent Cap O-Ring

    9. Vent Cap

    10. Lower Housing Collar

    11. 120VAC Pre-Heater

    12. 12VDC Pre-Heater

    13. Drain Valve

    Fig. 3, DAVCO Fuel Pro 482

  7. Clean all threads and sealing surfaces very thoroughly. Even a small amount of dirt will prevent the fuel/water separator from sealing, and an air leak may result.
  8. On Fuel Pro 382 units, install the grommet on the bottom of the new filter.
  9. Install the new filter and grommet assembly and cover O-ring on the housing.
  10. Install the clear cover and the collar. Simultaneously apply downward pressure to the top of the clear cover until it is seated on the body of the lower housing and hand tighten the collar until it no longer spins freely. Using the collar wrench, tighten the cover 18 lbf·ft (24 N·m). This is equivalent to rotating the collar clockwise two or three additional ribs, depending on the specific filter model.
  11. Prime the system.
    1. Ensure that the drain valve is closed.
    2. Fill the housing to the top of the filter element with clean diesel fuel.
    3. Install and hand-tighten the vent cap O-ring and vent cap.
    4. Start the engine. When the lubricating oil reaches its normal operating pressure, increase engine speed to high idle for one to two minutes to purge air from the system.
    5. While the engine is running, and after the air is purged from the system, loosen the vent cap until the fuel level falls to about one inch (2.5 cm) above the collar, then hand-tighten the vent cap.
    6. Check for leaks and shut down the engine.
Note:
Parent topic: Fuel/Water Separator Element Check and Replacement
Document Number: 0000120179
Manual Publication Date: 2024-05-23
Topic Publication Date: 2024-11-06