PureFlow AirDog® AirDog® FP-100 & FP-150 2005 and Up Cummins Diesel #4 CANADIAN PATENT 2,108,391 PROTECTED BY US PATENTS AUSTRALIAN PATENT 5,355,860; 5,746,184; 6,729,310 2005101054 NEW ZEALAND PATENT 532356 Additional Foreign Patents Pending in Europe, South America, Mexico, Japan, and China!
PureFlow AirDog® AirDog® FP-100 & FP-150 2005 and Up Cummins Diesel SMALL and COMPACT 7” Long X 3.
PureFlow AirDog® AirDog® FP-100 & FP-150 2005 and Up Cummins Diesel OVERVIEW Welcome to PureFlow® AirDog® Fuel Air Separation System for the Diesel Engine! The AirDog® Fuel Air Separation system is a Premium replacement lift pump and filtration system for the Dodge Cummins 24 Valve 5.9L diesel engines with the CP3 and in-tank factory lift pump. 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.
PureFlow AirDog® AirDog® FP-100 & FP-150 2005 and Up Cummins Diesel 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.
PureFlow AirDog® AirDog® FP-100 & FP-150 Section 1 2005 and Up Cummins Diesel Table of Contents TABLE OF CONTENTS Section 1……………………………………………………………….…………………...........……………Table of Contents Section 2…………………………………………………………………..…………....Installation and Safety Guidelines Section 3……………………………………………………………………….………………………………….....……….Parts List INSTALLATION PROCEDURES Section 4…………………………………………………………….….……….…....….Fittings, Brackets, and Mounting FUEL LINES Section 5……………………………………………………………………………………………..
PureFlow AirDog® AirDog® FP-100 & FP-150 Section 2 2005 and Up Cummins Diesel Installation and Safety Guidelines 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.
PureFlow AirDog® AirDog® FP-100 & FP-150 Section 3 2005 and Up Cummins Diesel Parts List AirDog® Parts List QTY DESCRIPTION Part Number 1 AirDog® FP-100-D12 Or FP-150-D12 1 AirDog® Mounting Bracket 001-3C-0004 1 Mounting Bracket Hardware Kit, Includes: 901-61-0102-PM Frame Bracket Set 010-3C-0002 010-3C-0001 Wiring Harness 5E-2-014 Return Fuel Filler Tube (with 2 Clamps) 001-4A-1-0150 Bundle of Plastic Ties 5H-2-1-06/12 1 1 1 1 1 7 High Flow Suction Tube (For FP-150’s Only) WAP108
PureFlow AirDog® AirDog® FP-100 & FP-150 Section 3 2005 and Up Cummins Diesel Parts List ILLUSTRATION OF QUICK CONNECT COMPONENTS 8
PureFlow AirDog® AirDog® FP-100 & FP-150 Section 4 2005 and Up Cummins Diesel Fittings, Brackets, and Mounting Installing the AirDog® Fittings & Mounting the Bracket on the Truck’s Frame Rail 4-1. Dip the threaded end of the 1/2” male J2044 quick connect x 3/4” UNF fittings (08J20443/4UNF) into clean motor oil and hand-thread into the “ENGINE” and “FUEL IN” ports in the AirDog®. Using a 7/8" deep socket, torque these fittings to 180in-lb or 15ft-lb.
PureFlow AirDog® AirDog® FP-100 & FP-150 Section 4 (Continued) 4-3. 2005 and Up Cummins Diesel Fittings, Brackets, and Mounting Attach the AirDog® to the frame bracket assembly as shown in figure 6 using the supplied hardware in the mounting bracket hardware kit (P/N 901-61-0102-PM). You will need a 3/16” Allen and a 7/16” wrench. Figure 6 NOTE: We recommend installing the AirDog® on the inside of the frame rail, but we understand some applications just don’t have the room.
PureFlow AirDog® AirDog® FP-100 & FP-150 Section 4 (Continued) 2005 and Up Cummins Diesel Fittings, Brackets, and Mounting NOTE: Be sure to mount the AirDog® so the ‘FUEL IN’ port is directed toward the rear of the vehicle(Figure 11). Fuel In Port Vehicle Rear Vehicle Front Figure 11 NOTE: Some pickup model frame rails have a bracket that is used to support the frame during the manufacturing process.
PureFlow AirDog® AirDog® FP-100 & FP-150 Section 5 2005 and Up Cummins Diesel Fuel line Assembly Assembling the Fuel Lines This kit includes a length of fuel line and separate fuel line ends to allow for much cleaner looking installations! Assemble the fuel lines as you install them. You won’t want to pre-assemble the hoses or your lengths may be off. 5-1.
PureFlow AirDog® AirDog® FP-100 & FP-150 Section 6-A 2005 and Up Cummins Diesel Fuel lines (Supply Line 5.9L) Installing the Fuel Supply Line from the AirDog® to the CP3 Injection Pump 5.9L When installing the AirDog® fuel system, it is recommended to bypass the factory filter canister for optimum engine performance. 6A-1. Using a 17mm wrench, remove the “banjo bolt” (Highlighted in Figure 18) and the original factory fuel supply line at the fuel inlet port of the CP-3 high pressure pump. Figure 18 6A-2.
PureFlow AirDog® AirDog® FP-100 & FP-150 Section 6-A (Continued) 6A-3 2005 and Up Cummins Diesel Fuel lines (Supply Line 5.9L) Assemble one end of the hose (Reference section 5) using Fuel line end FQC1290 and plug it into the WAP102 fitting installed in the previous step. A “click” will be heard once the fitting is properly connected. FQC1290 Figure 20 HS20 6A-4. Run the fuel line along the frame as mentioned in step 5-3 to the “Engine” port in the AirDog®.
PureFlow AirDog® AirDog® FP-100 & FP-150 Section 6-B 2005 and Up Cummins Diesel Fuel lines (Supply Line 6.7L) Installing the Fuel Supply Line from the AirDog® to the CP3 Injection Pump 6.7L When installing the AirDog® fuel system, it is recommended to bypass the factory filter canister for optimum engine performance. 6B-1. Using a 17mm wrench, remove the “banjo bolt” (Highlighted “2” in Figure 23) and the original factory fuel supply line at the fuel inlet port of the CP-3 high pressure pump.
PureFlow AirDog® AirDog® FP-100 & FP-150 Section 6-C 2005 and Up Cummins Diesel Fuel lines (Return Line to Tank) AirDog® Fuel Return Line Installing the fuel 'Return to Tank' assembly in Filler Tube 6C-1. Cut filler tube as illustrated in figure 25, removing 1/2 inch of hose. Loose assemble the clamps on each end of filler tube before the filler tube is pushed in. 6C-2. Insert the “Return Fuel Filler Tube” assembly (P/N 001-4A-1-0150) in the filler tube.
PureFlow AirDog® AirDog® FP-100 & FP-150 Section 6-D 2005 and Up Cummins Diesel Fuel lines (Suction Line from Tank) Fuel Suction Line for AirDog® FP-100 and FP-150 6D-1. Assemble one end of the suction fuel line (reference section 5) using fuel line end FQC12S. Once the end is pressed in, connect it to the J2044 fitting in the “Fuel In” port on the AirDog® A “click” will be heard when the fitting is properly connected. HS20 FQC12S Figure 30 HIGH FLOW SUCTION TUBE 6D-2.
PureFlow AirDog® AirDog® FP-100 & FP-150 Section 6-D (Continued) 2005 and Up Cummins Diesel Fuel lines (Suction Line from Tank) If you choose to remove the bed, properly support the truck bed to prevent serious injury or death! Figure 34 Figure 35 NOTE: The fuel tank and truck bed used for the pictures are examples 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.
PureFlow AirDog® AirDog® FP-100 & FP-150 Section 6-D (Continued) 2005 and Up Cummins Diesel Fuel lines (Suction Line from Tank) 6D-4. Drill a 1-1/8” hole at the selected location (Figure 38) in the fuel tank for the suction tube. Hold a container below the drill point to catch debris as shown in figure 39. Figure 39 Figure 38 6D-5. Remove all burrs from the edge of the hole as shown in figure 40. Figure 40 6D-6.
PureFlow AirDog® AirDog® FP-100 & FP-150 Section 6-D (Continued) 2005 and Up Cummins Diesel Fuel lines (Suction Line from Tank) 6D-8. Lubricate the bulkhead fitting on part WAP108 with clean motor oil. Pressing firmly, insert the suction tube assembly (WAP108) into the grommet (Figure 43). Be sure the bulkhead fitting is completely seated in the grommet. Bulkhead Fitting Figure 43 Figure 44 6D-9. Re-install the Collection basket.
PureFlow AirDog® AirDog® FP-100 & FP-150 Section 7 2005 and Up Cummins Diesel Wiring Harness AirDog® Wiring Harness Install WIRING DIAGRAM INDICATOR LIGHT LEADS* AirDog® MOTOR LEAD MALE POWER LEAD JUMPER PLUGS INTO FACTORY HARNESS RELAY FUSE HOLDER WITH 20A FUSE PRESSURE SWITCH LEAD* BATTERY NEGATIVE LEAD BATTERY POSITIVE LEAD FEMALE POWER LEAD JUMPER PLUGS INTO FUEL MODULE Figure 47 *CAUTION: If the OPTIONAL Low Pressure Indicator Light is not used, be sure to insulate the two (2) #10 Indicator Li
PureFlow AirDog® AirDog® FP-100 & FP-150 Section 7 (Continued) 2005 and Up Cummins Diesel Wiring Harness Connecting the AirDog® Power Lead Jumpers 7-2. Remove the factory wire harness connection from the top of the fuel module as seen in (Figure 49) Figure 49 7-3. 7-4. 7-5. Plug the AirDog® female power lead jumper into the top of the fuel module. After a “click” is heard, slide the red locking clip over to lock the connection in place.
PureFlow AirDog® AirDog® FP-100 & FP-150 Section 7 (Continued) 2005 and Up Cummins Diesel Wiring Harness Connecting the power supply leads Continued 7-6B. Should you choose to connect the power supply leads directly to the battery, connect the Red (+) led to the Positive (+) post of the driver’s side battery. Connect the Black (-) lead to the Negative (-) post of the same battery. Red (+) Black (-) Figure 52 7-7.
PureFlow AirDog® AirDog® FP-100 & FP-150 Section 8 2005 and Up Cummins Diesel Initial Startup Procedures INITIAL START PROCEDURE The AirDog® is a self-priming system, however, to prevent potential damage to the system, it is recommended to fill the pre-filter with diesel fuel before initial startup. 8-1. Fill the water separator with diesel fuel. 8-2. Turn the starter key to the on/run position. 8-3.
PureFlow AirDog® AirDog® FP-100 & FP-150 Section 9 2005 and Up Cummins Diesel Fuel Filter and Water Seperator 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® FP-100 & FP-150 Section 10 2005 and Up Cummins Diesel Pressure Regulator Service Changing the Regulator Spring The AirDog® is shipped from the factory with the fuel pressure preset. For the1998.5-2004 Dodge Cummins the AirDog® fuel outlet pressure is preset at 15 PSI (±2). However, for some applications, you may desire to increase the pressure output from your AirDog®. To do this, you will need to install a higher tension spring.
PureFlow AirDog® AirDog® FP-100 & FP-150 Section 11 2005 and Up Cummins Diesel Cleaning the Gerotor Assembly 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.
PureFlow AirDog® AirDog® FP-100 & FP-150 Section 12 2005 and Up Cummins Diesel Warranty 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.
PureFlow AirDog® AirDog® FP-100 & FP-150 Section 12 (Continued) 2005 and Up Cummins Diesel Warranty 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.
