DF-100 & DF-165 w/Adjustable Regulator #11 INSTALLATION MANUAL CUMMINS POWERED DODGE TRUCKS Model Year 1994 THROUGH 1998 High Performance Demand Flow Fuel System With New Quick Connect Components PLEASE READ THIS MANUAL 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! DEMAND FLOW SERIES FLOWS ONLY THE AMOUNT OF FUEL THE ENGINE REQUIRES SMALL and COMPACT 7” Long X 3.
OVERVIEW Welcome to PureFlow AirDog’s AirDog®II Fuel Air Separation, Filtration and Delivery System for the Diesel Engine The AirDog®II 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®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 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®II & Mounting Brackets FUEL LINES Section 5 A…………………………..…………………..……Fuel To Engine Section 5 B…………………….....…….……...
PureFlow AirDog AirDog®II Dodge Cummins 1994 - 1998 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. Understand how the system operates and installation recommendations before beginning installation.
PureFlow AirDog AirDog®II Section 3 AirDog®II Parts QTY DESCRIPTION 1 Installation Manual 1 AirDog®II 1 AirDog®II Bracket Dodge Cummins 1994 - 1998 Parts List List Rev.
1 3/8” Male J2004 Quick Connect x 1/8” NPTF 2 5/16” Push Lock X ¼” Male NPT 4A-1-18-05-04 1 Injection Pump Return Tee 001-4A-1-0008 1 “P” Pump Flexible Return Line 4C-1-02-05-001 06J2044-1/8 NPTF ILLUSTRATION OF QUICK CONNECT COMPONENTS 8
PureFlow AirDog AirDog®II Dodge Cummins 1994 - 1998 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® 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 4-3.
PureFlow AirDog ® AirDog II Dodge 1994-1998 AirDogII & Mounting Brackets ® Section 4 Installing the AirDog® & Mounting Brackets on the Truck’s Frame, cont’d! NOTE: The AirDog®II can be mounted on the inside or the outside of the frame. Some bed and cab configurations may only allow system to mount on the outside of the frame. 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! 4-6.
PureFlow AirDog ® AirDog II Dodge Cummins 1994 - 1998 Fuel to Engine Section 5-A Installing the Fuel Supply Line from the AirDog®II to the P-7100! The AirDog®II fuel filter is 2 micron media. When installing the AirDog®II fuel system it is recommended to bypass the factory filter canister. 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®II Dodge Cummins 1994 - 1998 Section 5-B P-7100 Injector Pump and Injector Fuel Bleed Return Line to Tank! NOTE: Fuel is returned from the P-7100 fuel pump and also from the injector bleed line(s). The original 12 Valve Cummins configuration returns the fuel from the P-7100 injector pump (Ref. Fig 19) directly to the fuel tank while the injector bleed line is routed to the inlet port of the fuel filter head (Ref. Fig. 21) to be recycled back to the engine.
PureFlow AirDog AirDog®II Dodge Cummins 1994 - 1998 Engine Fuel Return to Tank Section 5-B P-7100 Injector Pump and Injector Bleed Line Return to Tank, cont’d! 5B-5. Connect the ‘P’ pump metal return line (Ref. Fig. 20) to the return “T” push lock fitting with the flex fuel line (Ref. Fig. 25). Figure 26 Figure 27 5B-6. Connect the original fuel return line to the other end of the Return “T” Push Lock Coupler fitting. Figure 28 NOTE: The mechanical fuel pump must be disabled by removing the plunger.
PureFlow AirDog AirDog®II DF-100 Dodge Cummins 1994 - 1998 Fuel Lines Section 5-C Fuel Return Line from the AirDog® DF-100 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 1½ 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 Dodge Cummins 1994 – 1998 Fuel Lines AirDog®II DF-100 Section 5-D Fuel Supply Line for AirDog®II DF-100 Only! NOTE: The AirDog®II DF-165 and DF-200 require a Fuel Module Up-Grade Kit. If you are installing an AirDog®II DF-165, skip Section 5-D and go directly to Section 5-F for installation instructions! Connecting the Fuel Supply Line from the Tank to AirDog® DF-100 Figure 34 5D-1.
PureFlow AirDog AirDogII ® Dodge Cummins 1994 - 1998 Fuel Lines Section 5-D Fuel Suction Line for AirDog® DF-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 II Dodge 1994-1998 Fuel Lines Section 5 E Fuel Suction Line for AirDog®II DF-165 5E-1. Insert the female quick connect end (see figure 41) 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. Figure 41 5E-2. Refer to the installation instructions within the fuel module upgrade kit. Install the fuel module upgrade kit. 5E-3.
PureFlow AirDog ® AirDog II Dodge 1998 ½ - 2004 Fuel Return Section 5 F Fuel Return to Tank for AirDog®II DF-165 5F-1 Insert the female quick connect end (Figure 33) of the “Return Hose Assembly” into the previously installed male fitting for the tank port (step 4-4). The fitting will “click” when properly installed. Figure 43 5F-2. Attach the other end of the “Return Hose Assembly” onto the male 3/8” quick connect on the top of the fuel module that was previously vacated by the factory suction line.
PureFlow AirDog ® AirDog II Dodge Cummins 1994 - 1998 Electrical Harness Section 6 The AirDog®II is equipped with a relay controlled wiring harness. WIRING DIAGRAM (In Red) Figure 45 The AirDog®II relay controlled wiring harness connects directly to the fuse panel.
PureFlow AirDog ® AirDog II Dodge Cummins 1994 - 1998 Electrical Harness Section 6 Connecting the AirDog®II 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. Insert the mini fuse tap into a spare fuse holder or key hot source on the panel that is “hot” when the starter key is turned to the on position.
PureFlow AirDog AirDog®II Dodge Cummins 1994 - 1998 Electrical Harness Section 6 Connecting the power supply leads, cont’d! 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. 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.
PureFlow AirDog AirDog®II Dodge Cummins 1994 - 1998 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 the pre-filter and fuel filter with diesel fuel before initial startup. 7-1. Turn the starter key to the on/run position. NOTE: It may be necessary to momentarily engage the starter in order for the ECM to energize the AirDog®II. 7-2.
PureFlow AirDog AirDog®II 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®II Dodge Cummins 1994 - 1998 AirDog® 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, Remove and clean the gerotor. you will need to re-use it. Be very careful not to damage the gerotor. Step 4 Step 5 Remove the O-rings and clean the inside of the gerotor pocket Step 6 Replace the center gear.
PureFlow AirDog AirDog®II Dodge Cummins 1994 - 1998 Pressure Regulator Section 10 AirDog®II 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.
Parts of an AirDog Motor Tower Assembly Gerotor Cap Base Asse mbly Output Side Suction Side Fuel Flow Dividers Water Separator Nipple Fuel filter Suction Tube and Nipple Gerotor Cap Gerotor Assembly Gerotor Cap O-Rings Pressure Regulator Less psi 26 More psi
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.
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.
