#37 DF-100, DF-165, & DF-200 INSTALLATION MANUAL DURAMAX DIESEL POWERED Chevy & GMC TRUCKS 2011 AND UP High Performance Fuel System With New Quick Connect Components! PLEASE READ THE 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! PRESET OR ADJUSTABLE PRESSURE REGULATOR SMALL RETURN LINE FOR AIR, VAPOR AND FOAM DEMAND FLOW SERIES FLOWS ONLY THE AMOUNT OF FUEL THE ENGINE DEMANDS SMALL and COMPACT 7” Long X 3.
OVERVIEW Welcome to PureFlow® AirDog®II Fuel Air Separation, Filtration and Delivery System for the Diesel Engine The AirDog®II Fuel Preporator®, the Original Fuel Air Separation System, is a premium fuel pump and complete filtration system for the DuraMax Diesel Engine. The system removes water, particulates and entrained air from the fuel. The entrained air separated from the fuel is returned to the tank through a small return line.
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 2011-2012 DuraMax Diesel Table of Contents Section 1 TABLE OF CONTENTS Section 1……………………………….……….……………..Table of Contents Section 2…………………………………........Installation & Safety Guidelines Section 3……………………………….………...………………..…….Parts List INSTALLATION PROCEDURES Section 4…………………….………….………AirDog®II & Mounting Brackets FUEL LINES Section 5 A……………………………….…..…..…..….…AirDog®II to Engine Section 5 B……………………..…………….....……....AirDog®II Suction Line Section 5 C……………………...……….……………….
PureFlow AirDog ® AirDog II Demand Flow Section 2 2011-2012 DuraMax Diesel Installation & Safety Guidelines AirDog® II 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. Understand how the system operates and installation recommendations before beginning installation. 3.
PureFlow AirDog ® AirDog II Demand Flow 2011-2012 DuraMax Diesel Parts List Section 3 AirDog®II Parts List 1 Installation Manual 1 AirDog®II 1 AirDog®II Mounting Bracket 201-1-0222 DF-100 DF-165 DF-200 001-3C-0004 Mounting Hardware Kit, 1 1 901-61-0102-PM-C-12 1 Wiring Harness Bundle of Plastic Ties Suction Hose Assembly 5E-2-010 5H-2-1-06/12 WAP128-8-11.
ILLUSTRATION OF QUICK CONNECT COMPONENTS 8
PureFlow AirDog ® AirDog II 2011-2012 DuraMax Diesel AirDog II & Mounting Brackets ® Section 4 Installing the AirDog® II & Mounting Brackets on the Truck’s Frame! Figure 2 Figure 3 4-1. Assemble the AirDog II mounting bracket to the frame bracket. 4-2. 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. Figure 4 Figure 5 Figure 6 Out to ENGINE FUEL IN 4-3.
PureFlow AirDog ® AirDog II 2011-2012 DuraMax Diesel AirDog & Mounting Brackets ® Section 4 Installing the AirDog® & Mounting Bracket on the Truck’s Frame, cont’d! 4-6. Mark mounting hole locations on frame jig bracket using the mounting bracket (001-3C0004) as a template. Or create a paper template from the mounting bracket (001-3C0004). Be sure to line the template up as described in order to get the proper clearance needed when pump is installed. Figure 9 Figure 10 4-7.
PureFlow AirDog AirDog ® 2011-2012 DuraMax Diesel Fuel Lines Section 5A Installing the AirDog II Fuel Supply Line to the Engine To install the AirDog II fuel supply line to the engine, you must first remove the (flexible) factory fuel line connecting the fuel tank to the frame mounted steel fuel line. It will be the larger of the two lines that are on the frame. NOTE: The fuel tank connections are located behind the tank shield.
PureFlow AirDog AirDog ® 2011-2012 DuraMax Diesel Fuel Lines Section 5A 5A-2. Disconnect the other end of the fuel supply line from the steel line. This connection is located between the frame bracket and the front of the fuel tank as shown in fig 15 on the previous page. You may now remove the 18” of factory flex line. 5A-3. Insert the female Quick Connect end (see figure 15) of the “Pressure Hose Assembly” into the male quick connect fitting previously installed in the port marked “ENGINE”.
PureFlow AirDog ® AirDog II 2011-2012 DuraMax Diesel Fuel Lines Section 5-C Fuel Suction Line for AirDog® II 5B-1. Insert the female quick connect end (see figure 18) of the “Suction Hose Assembly” into the previously installed male fitting in the “Fuel In” port. A “click” will be heard when the fitting is properly connected. Figure 18 5B-2.
PureFlow AirDog ® AirDog II 2011-2012 DuraMax Diesel Fuel Lines Section 5-C AirDog® Fuel Return Line! Installing the fuel 'Return to Tank' assembly in Filler Tube Filler Tube Fuel Return Fitting Hose Clamp Fuel Tank Figure 21 5C-1. Cut filler tube as illustrated, removing ½ inch. Loose assemble clamps on each end of filler tube. Figure 22 Figure 23 5C-2. Insert “Return Fuel Filler Tube” assembly in filler tube.
PureFlow AirDog ® AirDog II 2011-2012 DuraMax Diesel Electrical Harness Section 6 The AirDog®II is equipped with a relay controlled wiring harness.
PureFlow AirDog ® AirDog II Demand Flow 2011-2012 DuraMax Diesel Electrical Harness Section 6 Connecting the AirDog®II Relay Control 6-2. Remove the plastic housing (skirt) around the fuse box. On some models it may be necessary to remove the fender/cowl brace to allow access to the fuse box. 6-3. After accessing the fuse panel, use a test light or voltmeter to find a fuse terminal that is HOT only when the ignition is in the on position.
PureFlow AirDog ® AirDog II Demand Flow 2011-2012 DuraMax Diesel Electrical Harness, cont’d Section 6 Connecting the power supply leads, cont’d 6-4B. 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. Black (-) Red (+) Figure 32 6-5.
PureFlow AirDog ® AirDog II Demand Flow 2011-2012 DuraMax Diesel 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 pre-fill only the water separator 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. 7-3.
PureFlow AirDog ® AirDog II Demand Flow 2011-2012 DuraMax Diesel Fuel Filter & Water Separator 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. Typical fuel filter life is 15-20k miles depending on fuel quality.
PureFlow AirDog ® AirDog II Demand Flow 2011-2012 DuraMax Diesel AirDog®II Fuel Pump 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 Demand Flow 2011-2012 DuraMax Diesel Pressure Regulator Section 10 AirDog II DF-165 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.
Installing a New Filter 1. Clean the area around the filter head and groove or seal area. NOTE: Lubricate the seal with oil. Do not use diesel fuel to lubricate the seal. 2. Install a new fuel filter on the filter head. Turn clock-wise until the filter contacts the seal. Tighten the filter one full turn or follow tightening instructions on filter after contact with the seal has been made.
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 hereby provides the following limited warranty as to description, quality, merchantability, fitness for the PRODUCT’S purpose, productiveness, or any other matter of SELLER’S PRODUCT sold herewith. The 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.
