INSTALLATION MANUAL #36 FOR 24 VALVE 5.9L CUMMINS POWERED DODGE TRUCKS 1998 ½ THROUGH 2002 MODEL FRRP-100 FACTORY REPLACEMENT RAPTOR PUMP READ THESE INSTRUCTIONS THOROUGHLY BEFORE BEGINNING INSTALLATION PureFlow AirDog 705 MAUSOLEUM ROAD SHELBYVILLE, IN 46176 1-877-421-3187 WWW.PUREFLOWAIRDOG.
Adjustable Regulator MOUNTS IN THE SAME LOCATION AS THE OE TRANSFER PUMP 2
OVERVIEW Welcome to the Raptor™ FRRP Fuel Pump The Raptor™ FRRP-100 Fuel Pump is a Premium replacement lift pump for the Dodge Cummins 24 Valve 5.9L diesel engine. A complete installation kit is included. The output pressure for the 5.9L 24 Valve Cummins engine is factory set at 14/16 PSI. Pressure and flows are approximate as they will vary with fuel temperature and as the brushes wear in. The FRRP-100 is for stock 5.9L Cummins Diesels.
Parts List QTY DESCRIPTION Part Number 1 RAPTOR™ FRRP FUEL PUMP 1 Mounting Hardware Kit 1 Customer Service Oring Replacement Kit 1 ¾”-16 Oring Boss X -8 JIC Fitting 4A-1-02-08-08-S 1 Fitting, ½” Push Lock X -8 Female JIC Swivel Fitting, -8 Male JIC x -8 Female JIC Swivel, 90° Elbow 4A-1-09-08-08-B 1 1 Output Hose Assembly 1 12mm X ½” Male SAE J2044 Quick Connect Fitting Sealing Washer (installs on WAP102 fitting and factory inlet banjo) 3 FRRP-100 901-61-0102-FRRP 906-05-0100 4A-2-04-0
ILLUSTRATION OF COMPONENTS 5
INSTRUCTIONS REMOVING THE STOCK PUMP FIG 1. (SOURCE: alldatapro.com) 1. Disconnect the electrical connector. Reference #6 of Fig. 1 2. Remove the banjo fitting on the inlet side of the stock fuel pump. Reference #4 of Fig 1. Do not discard this banjo fitting. It will be reused. 3. Remove the banjo fitting from inlet of the filter canister. 4. Remove the fuel line support from the mounting bracket. Reference #3 of Fig 1. 5. Remove the 3 mounting nuts at the top of the bracket. Reference #2 of Fig 1. 6.
INSTALLING THE FRRP-100 1. Replace the 2 original sealing washers on the stock banjo fitting with the 2 new ones provided (part# 1P-5-DS). 2. Firmly tighten the factory fuel supply line in the inlet port of the FRRP using the factory banjo fitting. The factory support bracket is no longer used. 3. Install the Boss O-ring fitting (part# 4A-1-02-08-08-S) into the outlet port of the FRRP and tighten firmly. 4. Firmly tighten the FRRP to the stock bracket using the hardware supplied. See Fig 2 Fig 2 5.
INSTALLING THE FRRP-100 CONTINUED 7. Cut the open end of the “Output Hose Assembly” to the desired length (a section of hose and a hose splice have been included if additional hose length is required) and install the ½” push lock x -8 swivel (part# 4A-1-09-08-08-B) into the end. See Figures 6 & 7 Figure 6 Figure 7 Lubricate the fitting with oil. Push the hose completely on the barb. 8. Loosely install the male end of the 90° elbow (part# 4A-2-04-08-08-S) on the hose assembly. 9.
Adjusting the Pressure Regulator NOTE: PureFlow AirDog strongly recommends the use of a fuel pressure gauge to monitor the output pressure on all of its fuel systems. To adjust the fuel pressure, loosen the lock nut on the regulator adjustment screw. Using a flat blade screw driver, rotate the adjustment screw clockwise to increase pressure or counter clockwise to decrease pressure. Be careful not to loosen the regulator assembly base. If you do, tighten it immediately.
PUREFLOW AIRDOG 4 YEAR LIMITED EXPRESS WARRANTY FOR Raptor™ FRRP-100 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 PRODUCT TO ONE (1) YEAR FROM THE DATE OF PURCHASE.
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. IN THE EVENT THAT THE BUYER DOES NOT AGREE WITH THIS AGREEMENT, THE BUYER MAY PROMPTLY RETURN THE PRODUCT, IN A NEW AND UNUSED CONDITION, WITH A DATED PROOF OF PURCHASE, TO THE PLACE OF PURCHASE WITHIN THIRTY (30) DAYS FROM THE DATE OF PURCHASE FOR A FULL REFUND.
