INSTALLATION MANUAL #25 FOR 12 VALVE 5.9L CUMMINS POWERED DODGE TRUCKS 1994 THROUGH 1998 MODEL RP-100 & RP-150 With New Quick Connect Components! PLEASE READ THESE INSTRUCTIONS THOROUGHLY BEFORE BEGINNING INSTALLATION PureFlow AirDog 705 MAUSOLEUM ROAD SHELBYVILLE, IN 46176 1-877-421-3187 www.pureflowairdog.
Wire Screen Insert In Fuel Inlet To Protect the Gerotor Fuel Inlet NOW On Left Side Adjustable Regulator 2
OVERVIEW Welcome to the Raptor™ Fuel Pump The Raptor™ Fuel Pump is a Premium replacement lift pump for the Dodge Cummins 12 Valve 5.9L diesel engine. A complete installation kit is included. The output pressure for the 5.9L 12 Valve Cummins engine is factory set at 25/30 PSI. Pressure and flows are approximate as they will vary with fuel temperature and as the brushes wear in. Also, per application through variation of vehicle voltage/amp output and fuel line installation.
QUICK CONNECT COMPONENT OVERVIEW Provided in this kit is an OE style quick connection system. This system allows 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 Raptor™ 100 & 150 1994 - 1998 Dodge Cummins Table of Contents Section 1 TABLE OF CONTENTS Section 1……………………………………..…………....…..Table of Contents Section 2……………………………….…………..……...…..Safety Guidelines Section 3……………………………….…………………….…..…..….Parts List INSTALLATION PROCEDURES Section 4…………………….……….……….…Raptor™ & Mounting Brackets FUEL LINES Section 5 A………………………………………..…The Mechanical Lift Pump Section 5 B……………………………….…...........Raptor™ To Filter Canister Section 5 C……………………………..……..
™ PureFlow AirDog Raptor 100 & 150 1994 - 1998 Dodge Cummins Safety Guidelines Section 2 Raptor™ MODEL RP-100 & RP-150 The installation of the Raptor™ Fuel Pump can be made relatively easy by following the steps outlined in this manual. 1. Inventory the package components completely. Notify PUREFLOW AIRDOG. immediately of any parts missing or damaged. 2. Read the installation manual and understand how the system operates before beginning installation. 3.
PureFlow AirDog Raptor™ 100 & 150 1994 - 1998 Dodge Cummins Parts List Section 3 Raptor Parts List QTY DESCRIPTION Part Number 1 INSTALLATION MANUAL 1 RAPTOR™ FUEL PUMP 205-1-0108 RP-100 Or RP-150 1 WIRING HARNESS 1 Frame Bracket Set 1 Mounting Hardware Kit 1 Cable Ties 1 Spacer 1 Suction Hose Assembly WAP110-8-6 1 Pressure Hose Assembly WAP110-8-8-90 1 Customer Service Oring Replacement Kit 2 Push Lock Hose Splice 2 1/2” Male QC x 3/4-16 ORB 1 12mm X ½” male SAE J2044 Fitt
ILLUSTRATION OF QUICK CONNECT COMPONENTS 8
PureFlow AirDog Raptor™ 100 & 150 Section 4 1994 - 1998 Dodge Cummins Raptor™ Fuel Pump & Mounting Brackets Section 4: Mounting the Raptor™ to the Truck’s Frame. The Raptor™ Fuel Pump is best mounted with the electric motor up, as shown. 4-1. Install 1/2” O-ring Boss X 3/4” male fitting (08J2044-3/4) into the Raptor™ port marked “IN”. FUEL “IN” PORT FUEL “OUT” PORT Figure 2 4-2. Install 1/2” O-ring Boss X 3/4” male fitting (08J2044-3/4UNF) into the port marked “OUT”. Properly torque the fitting.
PureFlow AirDog Raptor™ 100 & 150 1994 - 1998 Dodge Cummins Fuel Lines Section 5 Section 5A: The Factory Mechanical Lift Pump. NOTE: The mechanical fuel pump must be disabled by removing the plunger or removed from the engine. 5A-1. Remove the factory lift pump by removing the bolts securing it to the engine. 5A-2. Remove the plunger from the rear of the pump and re-install the mechanical pump. OR Figure 7 5A-3.
PureFlow AirDog Raptor™ 100 & 150 1994 - 1998 Dodge Cummins Fuel Lines Section 5 Section 5C: Connecting the Raptor™ to the Filter Canister. 5C-1. Install the 12mm x ½” male SAE J2044 (WAP 102) fitting with the seal washer supplied into the inlet port of the fuel filter head. Properly torque the fitting. Figure 13 5C-2 Insert the female quick connect end (see figure 14) of the “Pressure Hose Assembly” into the male quick connect fitting previously installed in the port marked “OUT”.
PureFlow AirDog Raptor™ 100 & 150 1994 - 1998 Dodge Cummins Fuel Lines Section 5D Connecting the Raptor™ to the Fuel Tank. 5D-1. Remove the original fuel suction line from fuel tank by squeezing the tabs on the end of the Quick Connect connector together and carefully removing it from the suction tube. Figure 16 Figure 17 (In more detail) To release the original fuel supply line from the fuel tank suction tube, center and firmly push the factory Quick Connect fitting against the suction tube.
PureFlow AirDog Raptor™ 100 & 150 1989-1993 Dodge Cummins Fuel Section 5D Lines Connecting the Raptor™ to the Fuel Tank Cont’d. 5D-4. Any excess fuel hose can be addressed by routing the hose in a fashion to take up the extra length, or a section of the hose can be removed. Push lock splices have been included if you choose to remove the excess hose.
PureFlow AirDog Raptor™ 100 & 150 1994 - 1998 Dodge Cummins Electrical Harness Section 6 WIRING DIAGRAM Figure 20 Installing the Raptor™ Fuel Pump wiring harness. 6-1. Connect the Power Supply Lead to the Raptor™, by inserting the 2 pin Deutsch connector on the end of the wiring harness into the corresponding connector on the Raptor™. Figure 21 6-2. Crimp the male spade connector on the end of the Red (+) wire.
PureFlow AirDog Raptor™ 100 & 150 Dodge Cummins 1994 - 1998 Final Check List Section 7 INITIAL START PROCEDURE 7-1. Turn the starter key to the on/run position. 7-2. While the Raptor™ Fuel Pump is on and pumping fuel, bleed the fuel line to the filter head by loosening the fuel line connection at the filter head. As soon as the line is purged of air and fuel is observed, properly tighten the fuel fitting. NOTE: put a rag or shop towel over and around the fitting to prevent splatter.
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.
