#2 MODEL FP-100 & FP-150 INSTALLATION MANUAL CUMMINS POWERED DODGE TRUCKS Model Year 1994 THROUGH 1998 High Performance Fuel System! With New Quick Connect Components! READ 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! SMALL and COMPACT 7” Long X 3.
OVERVIEW Welcome to PureFlow® AirDog® Fuel Air Separation, Filtration and Delivery System for the Diesel Engine! The AirDog® Fuel Air Separation system is a Premium replacement lift pump and filtration system for the Dodge Cummins 5.9L 12 Valve diesel engine. A complete installation kit is included. The AirDog® 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.
PureFlow AirDog ® AirDog FP-100 & FP-150 Dodge 1994-1998 QUICK CONNECT COMPONENT OVERVIEW Provided in this kit is an OE style Quick Connect 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.
PureFlow AirDog AirDog® 100 & 150 Dodge Cummins 1994 - 1998 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® & Mounting Brackets FUEL LINES Section 5 A………….…..
PureFlow AirDog AirDog® 100 & 150 Dodge Cummins 1994 - 1998 Installation & Safety Guidelines Section 2 AirDog® MODEL FP-100 & FP-150 The installation of your AirDog® 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® 100 & 150 Dodge Cummins 1994 - 1998 Parts List Section 3 AirDog® Parts List QTY DESCRIPTION Part Number 1 Installation Manual 1 AirDog® 201-1-0102 FP-100 Or FP-150 1 AirDog® Mounting Bracket 001-3C-0004 Mounting Hardware Kit, 1 901-61-0102-PM 010-3C-0002PC 010-3C-0001PC 1 Frame Bracket Set 1 1 Wiring Harness Bundle of Plastic Ties 1 Return Fuel Filler Tube (with 2 Clamps) 1 “P” Pump Flexible Return Line 1 High Flow Suction Tube (For FP-150’s Only) 1 Grommet
3 Push Lock Hose Splice 001-4A-1-0026 2 1/2” Male SAE J2004 Quick Connect x 3/8” NPTF 2 5/16” Push Lock X ¼” Male NPT 4A-1-18-05-04 1 Injection Pump Return Tee 001-4A-1-0008 08J2044-3/8 NPTF ILLUSTRATION OF QUICK CONNECT COMPONENTS 8
PureFlow AirDog AirDog® 100 & 150 Dodge Cummins 1994 - 1998 Parts List Section 4 Installing the AirDog® & Mounting Brackets on the Truck’s Frame! Figure 2 Figure 3 4-1. Assemble the AirDog® 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. 4-3.
PureFlow AirDog ® AirDog FP-100 & FP-150 Dodge 1998.5 - 2004 AirDog & Mounting Brackets ® Section 4 Installing the AirDog® & Mounting Brackets on the Truck’s Frame, cont’d! NOTE: The AirDog® 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 8 Figure 9 Inside The Frame Figure 10 Figure 11 For this installation, the AirDog® is mounted inside the frame! 4-5.
PureFlow AirDog AirDog® 100 & 150 Dodge Cummins 1994 - 1998 Fuel to Engine Section 5-A Installing the Fuel Supply Line from the AirDog® to the P-7100! For optimum engine performance, it is recommended to bypass the factory filter canister when installing the AirDog® fuel system. 5A-1. Remove the 14mm banjo bolt and original factory fuel supply line at the fuel inlet port of the P-7100 injector pump and from the original fuel filter head outlet port.
PureFlow AirDog AirDog® 100 & 150 Dodge Cummins 1994 - 1998 Fuel to Engine Section 5-A NOTE: It is not necessary or recommended to keep the factory filter canister in the system, the additional flow restriction of the factory filter could cause excessive pressure drops. Section 5-B: P-7100 Injector Pump and Injector Bleed Line Return NOTE: Fuel is returned from the P-7100 fuel pump and also from the injector bleed line(s).
PureFlow AirDog AirDog® 100 & 150 Dodge Cummins 1994 - 1998 Engine Fuel Return to Tank Section 5-B P-7100 Injector Pump and Injector Bleed Return Line, cont’d! 5B-5. Connect the ‘P’ pump metal return line (Ref. Fig. 26) to the return “T” push lock coupler fitting with the flex fuel line (Ref. Fig. 25). Figure 26 Figure 27 NOTE: Be sure to plug or cover the port in the fuel pump vacated by the fuel line to prevent contamination of the pump. 5B-6.
PureFlow AirDog AirDog® 100 & 150 Dodge Cummins 1994 - 1998 Section 5-C Fuel Lines 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 31 5C-1. Cut filler tube as illustrated, removing ½ inches. Loose assemble clamps on each end of filler tube. Figure 32 Figure 33 5C-2. Insert “Return Fuel Filler Tube” assembly in filler tube.
PureFlow AirDog AirDog® 100 & 150 Dodge Cummins 1994 - 1998 Fuel Suction Line Section 5-D Fuel Suction Line for AirDog® FP-100! NOTE: The AirDog® FP-150 requires a High Flow Suction Tube. If you are installing an AirDog® FP-150 skip Section 5D and go to section 5E for these installation instructions! Connecting the Fuel Suction Line from the Tank to AirDog® FP-100 Figure 34 5D-1.
PureFlow AirDog ® AirDog FP-100 & FP-150 Dodge Cummins 1994 - 1998 Fuel Lines Section 5-D Fuel Suction Line for AirDog® FP-100, cont’d 5D-2 Very Important: After removing the factory line check to make sure that the blue plastic retainer was removed with the line. If the blue retainer remained attached to the tank tube, it MUST be removed before the new fuel line Quick Connect will connect and seat to the tank suction tube. 5D-3.
PureFlow AirDog ® AirDog FP-100 & FP-150 Dodge Cummins 1994 - 1998 High Flow Suction Tube Section 5-E INSTALLING THE AIRDOG® FP-150 ONLY HIGH FLOW SUCTION TUBE The AirDog® 150 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 FP-100 & FP-150 Dodge Cummins 1994 - 1998 High Flow Suction Tube Section 5-E 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. 5E-1. Remove the collection basket. Figure 46 Figure 47 5E-2.
PureFlow AirDog ® AirDog FP-100 & FP-150 Dodge Cummins 1994 - 1998 High Flow Suction Tube Section 5-E INSTALLING THE HIGH FLOW SUCTION TUBE, Cont’d 5E-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 52. Figure 52 5E-6. Lubricate the bulkhead fitting with motor oil. Pressing firmly, insert the suction tube assembly into the grommet.
PureFlow AirDog ® AirDog FP-100 & FP-150 Dodge Cummins 1994 - 1998 High Flow Suction Tube Section 5-E INSTALLING THE HIGH FLOW SUCTION TUBE, Cont’d 5E-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. Section 6 Electrical Harness The AirDog® is equipped with a relay controlled wiring harness.
PureFlow AirDog ® AirDog FP-100 & FP-150 Dodge Cummins 1994 - 1998 Electrical Harness Cont’d Section 6 Securing the Relay and Fuse Holder to the Vehicle 6-1. Secure the relay and fuse holder to the vehicle. Figure 58 Figure 59 ® Connecting the AirDog Relay Control to the Fuse Panel 6-2. Route the red, Relay Trigger, wire with the mini fuse tap attached to the fuse panel located inside the cab on the driver’s side.
NOTE: The power supply leads can be connected to the battery or the alternator. Connecting the power supply leads to the alternator instead of the battery will create a corrosion free connection. Black (-) Red (+) Replace the Protective Cover Figure 62 Figure 63 6-4A. Route the Red & Black power supply leads to the alternator Connect the Black (-)lead to the alternator Chassis Ground connection. Connect the Red (+) lead to the alternator Hot Lead going to the battery. 6-4B.
PureFlow AirDog AirDog® 100 & 150 Dodge Cummins 1994 - 1998 Initial Startup Procedures Section 7 INITIAL START PROCEDURE The AirDog® is a self priming system, however, to prevent potential damage to 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. 7-3.
PureFlow AirDog AirDog® 100 & 150 Dodge Cummins 1994 - 1998 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. Typical fuel filter life is 15-20k miles depending on fuel quality.
PureFlow AirDog AirDog® 100 & 150 Dodge Cummins 1994 - 1998 AirDog® Fuel Pump Section 9 Cleaning Foreign Debris from the Gerotor Assembly Step 1 Remove the four (4) socket head cap crews that secure the gerotor cap. Step 4 Clean the inside of the gerotor pocket. Step 2 Step 3 Carefully remove the O’ring, Remove and clean the gerotor. you will need to re-use it. Be very careful not to damage the gerotor. Step 5 Replace the O’ring and center gear. Step 6 Align the teeth and install the outer gear.
PureFlow AirDog AirDog® 100 & 150 Dodge Cummins 1994 - 1998 Pressure Regulator Upgrade Section 10 Changing the Regulator Spring The AirDog® is shipped from the factory with the fuel pressure preset. For the 1994-1998 Dodge Cummins, the AirDog® fuel outlet pressure is preset at 25/30 PSI. Should the need arise to change the spring follow the instructions outlined below. Regulator Spring Replacement Procedure The regulator spring and ball assembly is located inside the Return to Tank fuel port. Step 1.
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.
