FP-100 & FP-150 INSTALLATION MANUAL CUMMINS POWERED DODGE TRUCKS Model Year 2005 THROUGH 2009 High Performance Replacement Fuel System For the 5.9L & 6.7L Engine PLEASE READ THE INSTRUCTIONS THOROUGHLY BEFORE BEGINNING INSTALLATION 1412 CREEK TRAIL DRIVE JEFFERSON CITY, MO 65109 573 635-0555 VOICE 573 635-0778 FAX www.pureflowtechnologies.
Approved for Sale and Use in California by CARB! SMALL and COMPACT 7” Long X 3.2” Wide X 10” Tall LIFETIME LIMITED EXPRESS WARRANTY NOTICE! To register your LifeTime Limited Express Warranty, you must fill out and return the enclosed Product Registration/Warranty card with a copy of the original sales receipt to PureFlow® Technologies Within Thirty Days of Purchase.
OVERVIEW Welcome to PureFlow® Technology’s 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 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® Technologies, Inc AirDog® FP-100 & FP-150 Dodge 2005 - 2009 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…………………………….……………….AirDog® To 5.9 CP-3 Section 5 B…………………………………..............AirDog® To 6.7L CP-3 Section 5 C……………………...……….
PureFlow® Technologies, Inc AirDog® FP-100 & FP-150 Dodge 2005 - 2009 Installation & Safety Guidelines Section 2 AirDog® MODEL FP-100 & 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® TECHNOLOGIES, INC. immediately of any parts missing or damaged. 2. Read the installation manual completely.
PureFlow® Technologies, Inc AirDog® FP-100 & FP-150 Dodge 2005 - 2009 Parts List Section 3 AirDog® Parts List QTY DESCRIPTION 1 Installation Manual 1 AirDog® 1 AirDog® Mounting Bracket 1 Mounting Bracket Hardware Kit, Includes: Part Number ADI-D0508P 100/150 FP-100-D24 Or FP-150-D24 001-3C-0004 4ea Socket Head Cap Screws, 1/4-20 x 1-1/4" Lg.
PureFlow® Technologies, Inc AirDog® FP-100 & FP-150 Dodge 2005 - 2009 AirDog & Mounting Brackets ® Section 4 Section 4: Installing the AirDog® & 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. Figure 5 Use the aluminum 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. FUEL IN 4-3.
PureFlow® Technologies, Inc AirDog® FP-100 & FP-150 Dodge 2005 - 2009 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® Technologies, Inc AirDog® FP-100 & FP-150 Dodge 2005 - 2009 Fuel Lines Section 5-A Fuel Supply Line from the AirDog® to the CP-3 For the 5.9L Cummins Engine The AirDog® fuel filter is made by Fleetguard and has a 2 micron Stratapore™ media. When installing the AirDog® fuel system it is recommended to bypass the factory filter canister. 5A-1. Remove the “banjo bolt” and the original factory fuel supply line at the fuel inlet port of the CP-3 high pressure pump. Figure 14 Figure 15 5A-2.
PureFlow® Technologies, Inc AirDog® FP-100 & FP-150 Dodge 2005 - 2009 Fuel Lines Section 5-A Fuel Supply Line from the AirDog® to the CP-3 For the 5.9L Cummins Engine 5A-5. Connect one end of the fuel line to the fitting on the AirDog® port marked “ENGINE”. Properly torque the fitting. To “ENGINE” Figure 21 5A-6. Route and connect the other end of the fuel line with the 90o fitting to the fuel inlet fitting just installed on the CP-3.
PureFlow® Technologies, Inc AirDog® FP-100 & FP-150 Dodge 2005 - 2009 Fuel Lines Section 5-B Fuel Supply Line from the AirDog® to the CP-3 For Model Year 6.7L Engine, cont’d 5B-2. Install the 12mm x -8 flare fitting with the O-ring supplied into the inlet port of the CP-3 vacated by the original Quick Connect fitting. Properly torque the 12mm x -8 flare fitting. Figure 25 Caution: Do not over torque the 12mm fitting, IT COULD BREAK! 5B-3.
PureFlow® Technologies, Inc AirDog® FP-100 & FP-150 Dodge 2007.5 - 2009 Fuel Lines Section 5-B Fuel Supply Line from the AirDog® to the CP-3 For the 6.7L Cummins Engine 5B-6. Route and connect the other end of the fuel line to the fuel inlet fitting just installed on the CP-3. When tightening the swivel, use a back up wrench on the 12mm fitting to preventing breaking it. Figure 32 NOTE: It is NOT NECESSARY or recommended to keep the factory filter canister in the system.
PureFlow® Technologies, Inc AirDog® FP-100 & FP-150 Dodge 2005 - 2009 Fuel Lines Section 5-C Fuel Return Line from the AirDog® to the Tank Installing the fuel 'Return to Tank' assembly in Filler Tube Filler Tube Hose Clamp Fuel Tank Figure 34-A Figure 35-A 5C-1. Cut filler tube as illustrated, removing 1½ inches. Loose assemble clamps on each end of filler tube. Filler Tube Hose Clamp Fuel Tank Figure 34-B Figure 35-B 5C-2.
PureFlow® Technologies, Inc AirDog® FP-100 & FP-150 Dodge 2005 - 2009 Fuel Lines Section 5-C Fuel Return Line from the AirDog® to the Tank, cont’d 5C-4. NOTE: For the 5.9L CP-3 installation install a straight 90o -8 swivel x 1/2" Push Lock on the end of the fuel line connecting to the AirDog® return to tank. NOTE: For the 6.7L CP-3 installation install a 90o -8 swivel x 1/2" Push Lock on the end of the fuel line connecting to the AirDog® return to tank.
PureFlow® Technologies, Inc AirDog® FP-100 & FP-150 Dodge 2005 - 2009 Fuel Lines Section 5-D INSTALLING THE INTANK FUEL PUMP BYPASS SUCTION TUBE! NOTE: The AirDog® installation kit includes a Suction Tube to by pass the “in-tank fuel pump on the 2005 - 2009 Dodge. To install the 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® Technologies, Inc AirDog® FP-100 & FP-150 Dodge 2005 - 2009 Fuel Lines Section 5-D INSTALLING THE SUCTION TUBE TO BYPASS THE INTANK FUEL PUMP, Cont’d If you choose to remove the bed, properly support the truck bed to prevent serious injury or death! Figure 46 Figure 47 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.
PureFlow® Technologies, Inc AirDog® FP-100 & FP-150 Dodge 2005 - 2009 Fuel Lines Section 5-D INSTALLING THE SUCTION TUBE TO BYPASS THE INTANK FUEL PUMP, Cont’d 5D-3. Remove all burrs from the edge of the hole. Figure 52 Figure 53 5D-4. Install the grommet in the new suction tube access hole. 5D-5. Assemble the suction tube and -8 flare x 3/8 NPT 900 fitting to the bulkhead fitting as shown in Figure 52. Use diesel compatible thread sealer when assembling the NPT fittings to the bulkhead fitting.
PureFlow® Technologies, Inc AirDog® FP-100 & FP-150 Dodge 2005 - 2009 Fuel Lines Section 5-D The In-Tank Fuel Pump VERY IMPORTANT: Before re-installing the collection basket, it is necessary to disable the in tank fuel pump. 5D-8. You may either disconnect the power lead to the pump while the collection basket is out of the tank and accessible…… Figure 58 OR Locate and cut the power supply lead in the wire harness outside the tank 5D-9.
PureFlow® Technologies, Inc AirDog® FP-100 & FP-150 Dodge 2005 - 2009 Fuel Lines Section 5-E Connecting the Fuel Supply Line from the AirDog® to the Tank! 5D-1. Measure and cut the length of fuel line required to connect the fuel tank “SUCTION TUBE” to the AirDog® fuel inlet port marked "Fuel In". Figure 63 5E-2. Install a straight -8 JIC swivel x ½” Push Lock fitting on each end of the fuel suction line to the fuel tank suction tube. Lubricate the barb end of the Push Lock fitting with oil.
PureFlow® Technologies, Inc AirDog® FP-100 & FP-150 Dodge 2005 - 2009 Electrical Harness Section 6 The AirDog® wiring harness features all 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 70 ® The AirDog is activated by the ECM through a relay controlled wiring harness connecting directly to the original ECM Deutsch pump connector.
PureFlow® Technologies, Inc AirDog® FP-100 & FP-150 Dodge 2005 - 2009 Electrical Harness, cont’d Section 6 Connecting the AirDog® Relay Control to the ECM 6-2. To connect the AirDog® relay trigger lead to the ECM fuel pump lead, locate the Orange w/Red Stripe wire coming off of the Fuel Module (Fig. 75). The Orange w/Red Stripe wire will be the right hand wire coming out of the Fuel Module. Figure 74 Figure 75 Orange w/Red Stripe ECM fuel pump lead! 6-2.
PureFlow® Technologies, Inc AirDog® FP-100 & FP-150 Dodge 2005 - 2009 Electrical Harness, cont’d Section 6 Connecting the Wiring Harness to the AirDog® 6-5. Route the wiring harness to the AirDog® and connect the 2 pin Deutsch connector to the corresponding connector on the AirDog®. Figure 80 INSTALLING THE OPTIONAL LOW PRESSURE INDICATOR LIGHT 6-6. Remove the 1/8” npt plug located in the top of the base below the end of the motor.
PureFlow® Technologies, Inc AirDog® FP-100 & FP-150 Dodge 2005 - 2009 Initial Startup Procedures Section 7 INITIAL START PROCEDURE The AirDog® 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. Pre-fill the water separator with diesel fuel.
PureFlow® Technologies, Inc AirDog® FP-100 & FP-150 Dodge 2005 - 2009 Fuel Filter & Water Separator Section 8 Filter Service Recommendations Plugging of either the fuel filter or water separator will cause low fuel pressure and flow to the engine. Should you experience low pressure, first check the water separator for plugging and restriction. If the low fuel pressure issue continues, replace the fuel filter.
PureFlow® Technologies, Inc AirDog® FP-100 & FP-150 Dodge 2005 - 2009 Pressure Regulator Upgrade Section 9 Changing the Regulator Spring The AirDog® is shipped from the factory with the fuel pressure preset. For the 2005-2009 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® Technologies, Inc AirDog® FP-100 & FP-150 Dodge 2005 - 2009 AirDog® Fuel Pump Section 10 Cleaning Foreign Debris from the Gerotor Assembly Step 1 Remove the four (4) buttons 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 7 Install the Gerotor cap.
Copyright © 2009 PureFlow Technologies, Inc. All Right Reserved PFT Bulletin No.