#17 INSTALLATION MANUAL Model Year 2005 THROUGH PRESENT DF-200 w/Adjustable Regulator And New Quick Connect Components CUMMINS POWERED DODGE TRUCKS High Performance Fuel System PLEASE READ THESE INSTRUCTIONS THOROUGHLY BEFORE BEGINNING INSTALLATION! PureFlow AirDog 705 MAUSOLEUM ROAD SHELBYVILLE, IN 46176 1-877-421-3187 www.pureflowairdog.
Approved for Sale and Use in California by CARB! (Limited Edition Model Pictured) PRESET OR ADJUSTABLE PRESSURE REGULATOR SMALL RETURN LINE FOR AIR, VAPOR AND FOAM DEMAND FLOW SERIES FLOWS ONLY THE AMOUNT OF FUEL THE ENGINE REQUIRES SMALL and COMPACT 7” Long X 3.
OVERVIEW Welcome to PureFlow AirDog home of the AirDog®II Fuel Air Separation, Filtration and Delivery System for the Diesel Engine The AirDog®II, is a premium replacement fuel pump and complete filtration system for the Dodge Cummins Diesel Engine. The AirDog®II delivers clean fuel to the engine free of virtually all air/vapor and at a positive flow. Thus, allowing the engine “test cell” performance and efficiency, while in “real world” use.
QUICK CONNECT COMPONENT OVERVIEW Provided in this kit is an OE style quick connection system. This system works to allow for a quick, clean, and professional install. SAE J2044 Quick Connect System The SAE J2044 quick connect system is the most commonly used system in the automotive industry. The images below show the formation of SAE J2044 connection. To connect the assemblies, simply insert the male end form into the mating female connector. Push firmly until you hear it “click” into place.
PureFlow AirDog ® AirDog II DF-200 Dodge 2005 - 2011 Table of Contents Section 1 TABLE OF CONTENTS Section 1……………………………….…………………..Table of Contents Section 2…………………………………Installation and Safety Guidelines Section 3…………………………….……....……………………….Parts List INSTALLATION PROCEDURES Section 4…………………….…………...…AirDog®II & Mounting Brackets FUEL LINES Section 5 A………………………..………………………………….5.9L CP3 Section 5 B…………………………………………….…….……...6.7L CP3 Section 5 C……………………………………….………...Fuel Suction Line Section 5 D…………………….
PureFlow AirDog ® AirDog II DF-200 Dodge 2005 - 2011 Installation & Safety Guidelines Section 2 AirDog®II INSTALLATION GUIDELINES! The installation of your AirDog®II can be made relatively easy by following the steps outlined in this manual, and: 1. Inventory the package components completely. Notify PUREFLOW® AIRDOG immediately of any parts missing or damaged. 2. Read the installation manual completely.
PureFlow AirDog ® AirDog II DF-200 Dodge 2005 - 2011 Parts List Section 3 AirDog® Parts List QTY DESCRIPTION Part Number 1 Installation Manual 201-1-0124-200 DF-100 DF-165 DF-200 1 AirDog®II 1 AirDog®II Mounting Bracket 1 Mounting Hardware Kit, 901-61-0102-PM 1 Frame Bracket 010-3C-0002PC 010-3C-0001PC 1 Wiring Harness 5E-2-014 1 Bundle of Plastic Ties 1 High Flow Suction Tube 1 Spacer 1 Suction Hose Assembly WAP110-8-8 1 Return Hose Assembly WAP112-8-8 1 Pressure Hose As
ILLUSTRATION OF QUICK CONNECT COMPONENTS 8
PureFlow AirDog ® AirDog II DF-200 Dodge 2005 - 2011 AirDog II & Mounting Brackets ® Section 4 Installing the AirDog II® & Mounting Brackets on the Truck’s Frame! Figure 2 4-1. Figure 3 Assemble the AirDog® mounting bracket to the frame bracket. Figure 4 4-2. 4-3. Figure 5 Use the spacer block to clear lines and wiring harnesses on the frame. Adjust the assembly up or down on the frame bracket as necessary for clearance.
PureFlow AirDog ® Dodge 2005 – 2011 AirDog & Mounting Brackets AirDog II DF-200 ® Section 4 Installing the AirDog® & Mounting Brackets on the Truck’s Frame, cont’d! NOTE: The AirDog®II can be mounted on either the inside or the outside of the frame, as space or personal choice dictates. Mount The AirDog® Outside The Frame OR Figure 9 Figure 10 Inside The Frame Figure 11 Figure 12 For this installation, the AirDog®II is mounted inside the frame! 4-5.
PureFlow AirDog ® AirDog II DF-200 Dodge 2005 - 2011 Fuel Lines Section 5 A Fuel Supply Line from the AirDog®II to the CP-3 For the 5.9L Cummins Engine When installing the AirDog®II fuel system it is recommended to bypass the factory filter canister. Fuel Line Specs Manufacturer: EATON Weatherhead Rated for Diesel Fuel Cover: Blue Vinyl Nitrile Inner Tube: Nitrile Reinforcement: 1 Fiber Braid Temp. Range: -40°F to +212°F Working Pressure 250 PSI Burst Pressure 1,000 PSI. 5A-1.
PureFlow AirDog ® AirDog II DF-200 Dodge 2005 - 2011 Fuel Lines Section 5 A Fuel Supply Line from the AirDog®II to the CP-3 For the 5.9L Cummins Engine, cont’d! NOTE: Having routed the fuel line directly to the CP3, it is suggested to cap or plug the inlet and outlet ports of the bypassed filter canister. BE SURE TO RECONNECT THE INJECTOR PUMP AND ENGINE RETURN LINES AS THEY WERE ORIGINALLY! Figure 17 Section 5 B Fuel Supply Line from the AirDog®II to the CP-3 For the 6.
PureFlow AirDog ® AirDog II DF-200 Dodge 2005 - 2011 Fuel Lines Section 5 B Fuel Supply Line from the AirDog®II to the CP-3 For the 6.7L Engine, cont’d 5B-3 Insert the female quick connect end (see figure 20) of the “Pressure Hose Assembly” into the male quick connect fitting previously installed in the port marked “ENGINE”. You will hear a “click” when it connects. Figure 20 5B-4. Connect the other end of the “Pressure Hose Assembly” to the inlet fitting previously installed in step 5B-2.
PureFlow AirDog ® AirDog II DF-200 Dodge 2005 - 2011 High Flow Suction Tube Section 5-C INSTALLING THE AIRDOG® HIGH FLOW SUCTION TUBE The AirDog® II DF-200 includes a ½” High Flow suction tube to accommodate the high flows of this system. To install the ½ suction tube it is necessary to either drop the fuel tank or to lift the truck bed. NOTE: Should you choose to drop the fuel tank, support the tank as it is when it is installed on the truck.
PureFlow AirDog ® AirDog II DF-200 Dodge 2005 - 2011 High Flow Suction Tube Section 5-C INSTALLING THE HIGH FLOW SUCTION TUBE, Cont’d NOTE: The fuel tank used for the pictures is an example only and may not be exactly the same as your tank. IMPORTANT: Select a location for the suction tube that has adequate clearance below the bed. Also consider that under hard acceleration, fuel will migrate toward the back of the fuel tank. 5C-1. Remove the collection basket. Figure 26 Figure 27 5C-2.
PureFlow AirDog ® AirDog II DF-200 Dodge 2005 - 2011 High Flow Suction Tube Section 5-C INSTALLING THE HIGH FLOW SUCTION TUBE, Cont’d 5C-5. Measure and cut the suction tube to a length that will allow approximately 1/8” clearance off the bottom of the tank. It is suggested to form the end of the tube similar to Figure 32. Figure 32 5C-6. Lubricate the bulkhead fitting with motor oil. Pressing firmly, insert the suction tube assembly into the grommet.
PureFlow AirDog ® AirDog II DF-200 Dodge 2005 - 2011 High Flow Suction Tube Section 5-C INSTALLING THE HIGH FLOW SUCTION TUBE, Cont’d 5C-10. If the fuel tank was dropped to install the suction tube, re-install the fuel tank. If the truck bed was removed, reinstall the bed. 5C-11. Insert the female quick connect end (see figure 36) of the “Suction Hose Assembly” to the male fitting previously installed in the “Fuel In” port. A “click” will be heard when the fitting is properly connected.
PureFlow AirDog ® AirDog II DF-200 Dodge 2005 - 2011 Fuel Return Line Section 5-D Fuel Return Line from the AirDog® to the Tank Installing the fuel 'Return to Tank' assembly in Filler Tube Filler Tube Fuel Return Fitting Hose Clamp Fuel Tank Figure 37 5D-1. Cut filler tube as illustrated, removing ½ inches. Loose assemble clamps on each end of filler tube. Figure 38 Figure 39 5D-2. Insert “Return Fuel Filler Tube” assembly in filler tube.
PureFlow AirDog ® AirDog II DF-200 Dodge 2005 - 2011 Electrical Harness Section 6 The AirDog® wiring harness features water proof Deutsch connectors, relay, and fuse holder. When properly installed, the AirDog® is controlled by the engine’s ECM. WIRING DIAGRAM (In Red) Figure 40 ® The AirDog is activated by the ECM through a relay controlled wiring harness connecting directly to the original ECM Deutsch pump connector.
PureFlow AirDog ® AirDog II DF-200 Dodge 2005 - 2011 Electrical Harness Section 6 Securing the Relay and Fuse Holder to the Vehicle 6-1. Secure the relay and fuse holder to the vehicle. Figure 42 Figure 43 Connecting the AirDog® Power Lead Jumpers 6-2. Remove the factory wire harness connection from the top of the fuel module as seen in (Figure 45) Figure 44 6-3. Plug the AirDog female power lead jumper into the top of the fuel module.
PureFlow AirDog ® AirDog II DF-200 Dodge 2005 - 2011 Electrical Harness, cont’d Section 6 OR 6-7. Should you choose to connect the power supply leads directly to the battery, connect the RED (+) lead to the POSITIVE (+) post of the driver's side battery. Connect the BLACK (-) lead to the NEGATIVE (-) post of the same battery. Figure 46 Connecting the Wiring Harness to the AirDog® 6-8.
PureFlow AirDog ® AirDog II DF-200 Dodge 2005 - 2011 Initial Startup Procedures Section 7 INITIAL START PROCEDURE The AirDog®II is a self priming system, however, to prevent potential damage and reduce the life expectancy of the system, it is recommended to fill only the pre-filter with diesel fuel before initial startup. 7-1. Fill the water separator with diesel fuel. 7-2. Turn the starter key to the on/run position.
PureFlow AirDog ® AirDog II DF-200 Dodge 2005 - 2011 Fuel Filter & Pre-filter Section 8 Filter Service Recommendations Plugging of either the fuel filter or the water separator itself will cause low fuel pressure and low flow to the engine. If a low fuel pressure issue exists, replace the fuel filter. AirDog® 2 Micron Fuel Filter AirDog® WATER SEPARATOR Drain Valve The Water Separator Replace the water separator every other time you change the Fuel Filter or if it becomes damaged or plugged.
PureFlow AirDog ® AirDog II DF-200 Dodge 2005 - 2011 Cleaning the Gerotor Assembly Section 9 Cleaning Debris from the Gerotor Assembly Step 1 Step 2 Remove the four (4) socket head cap crews that secure the gerotor cap. Step 3 Carefully remove the O-rings. you will need to re-use them. Step 4 Remove and clean the gerotor assembly. Be careful not to damage the gerotor. Step 5 Clean the inside of the gerotor pocket. Step 6 Replace the center gear.
PureFlow AirDog ® AirDog II –DF-200 Dodge 2005 - 2011 Pressure Regulator Section 10 AirDog®II DF-100, DF-165, & DF-200 with Adjustable Pressure Regulator! The AirDog®II rises to a new level of excellence with an Adjustable Regulator machined from stainless steel with a double O-ring seal system and a soft seat piston.
PUREFLOW AIRDOG LIFETIME LIMITED EXPRESS WARRANTY FOR Covered PureFlow AirDog I, II and Raptor Systems IMPORTANT NOTICE TO ACTIVATE YOUR PURFLOW AIRDOG WARRANTY, YOU MUST COMPLETE AND MAIL YOUR WARRANTY CARD TO PUREFLOW AIRDOG WITH A COPY OF YOUR ORIGINAL SALES RECEIPT WITHIN 30 DAYS OF PURCHASE. FAILURE TO COMPLETE AND SUBMIT YOUR WARRANTY CARD WILL RESULT IN A WARRANTY PERIOD OF THE COVERED PRODUCE TO ONE (1) YEAR FROM THE DATE OF PURCHASE.
SELLER shall be in no way responsible for the open use and service of the PRODUCT and the BUYER hereby waives all rights other than those expressly written herein. This Warranty shall not be extended or varied except by a written instrument signed by SELLER and BUYER.
