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Summary of Contents for PureFlow AirDog FP-100-4G
- Page 1 FP-100-4G FP-150-4G PATENT PROTECTED: https://pureflowairdog.com/p-35853-patents.html 1998.5-2004 CUMMINS INSTALLATION INSTRUCTIONS PLEASE READ AND CHECK CONTENTS BEFORE INSTALLATION PUREFLOW AIRDOG 705 W MAUSOLEUM RD. 877-421-3187 SHELBYVILLE, IN 46176 PUREFLOWAIRDOG.COM...
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Page 2: Table Of Contents
TABLE OF CONTENTS TITLE PAGE INTRODUCTION SAFETY GUIDELINES PRE-INSTALLATION CHECKS PARTS LIST QUICK CONNECT FITTING OVERVIEW QUICK CONNECT FITTING ILLUSTRATION PUMP TO FRAME INSTALLATION PUMP CRADLE BRACKET INSTALLATION PUMP TO FRAME INSTALLATION FUEL LINE ASSEMBLY OVERVIEW ENGINE LINE INSTALLATION VP-44 ENGINE LINE INSTALLATION CP3 FUEL FILTER HOUSING REMOVAL RETURN LINE INSTALLATION... -
Page 3: Introduction
INTRODUCTION Thank you for choosing AirDog® for your truck fueling needs! AirDog® recommends that a certified diesel shop technician install this product. Please note, if the end user performs the installation, it is recommended they have basic knowledge on how electric fuel systems operate and function. Failure to properly set up this fuel system may result in a voided warranty. -
Page 4: Safety Guidelines
SAFETY GUIDELINES SAFETY INSTRUCTIONS LEARN TO RECOGNIZE SAFETY INFORMATION This is the safety alert symbol. When you see this symbol in this manual, BE ALERT TO THE POTENTIAL FOR PERSONAL INJURY! Follow recommended precautions and safe operating practices. UNDERSTANDING SIGNAL WORDS A signal word-DANGER, WARNING, or CAUTION is used with the safety alert symbol. -
Page 5: Pre-Installation Checks
The installation of your AirDog® can be made relatively easy by following the steps outlined in this manual, and: Inventory the package components completely. Notify PUREFLOW AIRDOG® immediately of any missing or damaged parts! 317-421-3180 Read the installation manual completely. Understand how the system operates and understand the installation recommendations before beginning the installation. -
Page 6: Parts List
PARTS LIST DESCRIPTION PART NUMBER IMAGE AirDog® FP-100 OR FP-150 AirDog® Cradle Bracket 001-3C-0004 010-3C-0001 Frame Bracket Set 010-3C-0002 Mounting Bracket Hardware 901-61-0102-PM Spacer Block 010-3C-0003-A-P Wiring Harness 5E-2-011-HD High Flow Suction Tube (For FP-150 and WAP109 FP-100 with In Tank Pump Only) 1.5”... -
Page 7: Quick Connect Fitting Overview
OVERVIEW OF QUICK CONNECT FITTINGS WHY WE USE QUICK CONNECT FITTINGS Almost every modern vehicle on the road uses what are called quick connect fittings for their fuel system. These are standardized using J2044 SAE specifications. We use these fittings to make the installation of our fuel systems as simple and as least invasive as possible. -
Page 8: Quick Connect Fitting Illustration
ILLUSTRATION OF QUICK CONNECT COMPONENTS IMAGE NOT TO SCALE VIEW OF PUMP IS LOOKING DOWN THE PORTS ARE LABELED... -
Page 9: Pump To Frame Installation
INSTALLING THE PUMP FITTINGS TOOLS NEEDED: - Torque Wrench - 7/8” Deep Socket PARTS NEEDED: - (2) 08J2044-3/4UNF fittings 1-1. Dip the threaded end of the 1/2” male J2044 quick connect x 3/4” UNF fittings (08J2044-3/4UNF) into clean motor oil and hand-thread into the “ENGINE” and “FUEL IN”... -
Page 10: Pump Cradle Bracket Installation
INSTALLING THE PUMP ON THE BRACKET TOOLS NEEDED: - 3/16 Allen - 7/16 Socket or Wrench PARTS NEEDED: - (4) 1/4-20 x 1.25 Socket Head Cap Screws - (4) 1/4” Lock Washers - (4) 1/4-20 Nuts - (1) 001-3C-0004 Cradle Bracket 2-1. -
Page 11: Pump To Frame Installation
INSTALLING THE PUMP ON THE FRAME TOOLS NEEDED: - 3/16 Allen - 1/2 Socket or Wrench - 9/16 Socket or Wrench x2 PARTS NEEDED: - (4) 5/16-18 x 3.0” Flat Socket Head Cap Screws - (4) 5/16” Lock Washers - (4) 5/16-18 Nuts - (3) 3/8-16 x 4.5”... - Page 12 INSTALLING THE PUMP ON THE FRAME CONTINUED 3-2. Assemble the AirDog® mounting bracket (001-3C-0004) to the frame bracket (010-3C-0001) using the spacer (010-3C-0003-A-P) as shown in figure 3 using the four 5/16 bolts, lock washers, and nuts included in the mounting bracket hardware kit (figure 5).
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Page 13: Fuel Line Assembly Overview
FUEL LINE ASSEMBLY OVERVIEW This kit includes a length of fuel line and separate fuel line fittings to allow for a much cleaner looking installation. Assemble the fuel lines as you install them. Do not pre-assemble the fuel lines, or the lengths will not be correct. -
Page 14: Engine Line Installation
ENGINE LINE INSTALLATION VP-44 98.5-02 TOOLS NEEDED: - 13/16” Wrench or Extra Deep Socket - Clean Motor Oil or ATF - Hose Cutters or a way to cut Fuel Line - 17mm Wrench PARTS NEEDED: - (1) WAP102 Injection Pump Fitting - (1) 1P-5-DS Sealing Washer - (1) FQC12S 1/2”... - Page 15 ENGINE LINE INSTALLATION VP-44 98.5-02 CONTINUED 5a-3. Assemble one end of the hose (Reference section 4) 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 13 HS20...
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Page 16: Engine Line Installation Cp3
ENGINE LINE INSTALLATION CP3 03-04 When installing the AirDog® fuel system, it is recommended to bypass the factory filter canister for optimum engine performance. 5b-1. Using a 17mm wrench, remove the “banjo bolt” (Highlighted in Figure 15) and the original factory fuel supply line at the fuel inlet port of the CP-3 high pressure pump. -
Page 17: Fuel Filter Housing Removal
FUEL FILTER HOUSING REMOVAL It is not necessary to remove the fuel filter housings on these trucks. At the most, the line from the filter housing to the injection pump will need to be removed with a 17mm wrench. 6-1. The Filter Housing can be removed on the 98.5-02 VP-44 trucks as it is no longer used. -
Page 18: Return Line Installation
RETURN LINE INSTALLATION TOOLS NEEDED: - Clean Motor Oil or ATF - Hose Cutters or a way to cut Fuel Line and the Filler Neck PARTS NEEDED: - (1) 001-4A-1-0150 1.5” Filler Neck Return Tee with Clamps - (1) FQC1290 1/2“ 90deg Quick Connect Fitting - (1) FQC12S 1/2”... -
Page 19: Inlet Line Installation Fp-100
INLET LINE INSTALLATION FP-100 WITHOUT IN TANK PUMP TOOLS NEEDED: - Clean Motor Oil or ATF - Hose Cutters or a way to cut Fuel Line PARTS NEEDED: - (1) FQC38S 3/8“ Straight Quick Connect Fitting - (1) FQC12S 1/2” Straight Quick Connect Fitting - (1) HS20 20ft Fuel Line The AirDog®... - Page 20 INLET LINE INSTALLATION FP-100 WITHOUT IN TANK PUMPC ONTINUED 8-3. Run the fuel line along the frame as mentioned in step 4-3 to the AirDog® “Fuel In” port. Cut the fuel line to length and insert fuel line end FQC12S per step 4-1. Once the fuel line end is pressed in, connect it to the male J2044 fitting in the AirDog®...
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Page 21: Inlet Line Installation Fp-150
INLET LINE INSTALLATION FP-150 AND FP-100 WITH IN TANK PUMP TOOLS NEEDED: - Clean Motor Oil or ATF - Hose Cutters or a way to cut Fuel Line - 1” Hole Saw or Step Bit that can go up to 1” - Hammer - Large Screwdriver -7/8“... - Page 22 INLET LINE INSTALLATION FP-150 AND FP-100 WITH IN TANK PUMP- CONTINUED The FP-150 and FP-100 with in tank pumpREQUIRE the installation of this high flow suction tube or aftermarket sump! Failure to do so WILL cause pump failure and may void your warranty! 9-2.
- Page 23 INLET LINE INSTALLATION FP-150 AND FP-100 WITH IN TANK PUMP- CONTINUED Should you choose to pull the pickup bed to access the tank. Be sure to disconnect the tail light wires, fuel tank filler tube, and any other accessories or components that may be secured to the frame and bed.
- Page 24 INLET LINE INSTALLATION FP-150 AND FP-100 WITH IN TANK PUMP- CONTINUED 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. 9-3.
- Page 25 INLET LINE INSTALLATION FP-150 AND FP-100 WITH IN TANK PUMP- CONTINUED 9-5. Install fitting 08J2044-3/4UNF into the bulkhead fitting of the WAP109 draw straw, as shown, using a 7/8” wrench or deep socket. Tighten until the O-ring is no longer visible. Figure 36 9-6.
- Page 26 INLET LINE INSTALLATION FP-150 AND FP-100 WITH IN TANK PUMP- CONTINUED 9-7. Drill crossing pilot holes through the nylon tube, centered on the marked line, as shown (Figure 39). Use a larger bit (1/2” MAX) to open the holes up (Figure 40). Figure 39 Figure 40 9-8.
- Page 27 INLET LINE INSTALLATION FP-150 AND FP-100 WITH IN TANK PUMP- CONTINUED 9-10. Re-install the fuel module. Re-install the factory return line (The smaller of the two lines) to the proper port of the fuel module before the tank or bed is fully re-installed.
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Page 28: Wiring Installation
WIRING INSTALLATION DEUTSCH ECM CONNECTOR AirDog® MOTOR LEAD FUSE HOLDER RELAY WITH 20A FUSE BATTERY NEGATIVE LEAD BATTERY POSITIVE LEAD Figure 49 10-1. Secure the relay and fuse holder to the vehicle. Be sure to route the wires away from any moving parts. The relay is illustrated below in figure 50. The fuse holder mounting is the same concept. - Page 29 WIRING INSTALLATION CONTINUED 10-2. Disconnect the OE fuel pump lead from the ECM pump lead. The Original Equipment fuel pump lead extends about 5 inches from the pump. The Deutsch, two pin connector is at the end of this lead. Look for it below and to the rear of the filter canister.
- Page 30 WIRING INSTALLATION CONTINUED 10-4. 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 54...
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Page 31: Initial Starting Procedure
INITIAL STARTING 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. 11-1. Fill the water separator with clean diesel fuel. 11-2. Turn the starter key to the on/run position. 11-3. -
Page 32: Filter Service
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. AirDog®... -
Page 33: Servicing The Pump Gerotor
SERVICING THE PUMP GEROTOR CLEANING DEBRIS/CHECKING FOR DAMAGE IN/TO THE GEROTOR ASSEMBLY STEP 3: Remove and clean the STEP 1: Remove the four (4) STEP 2: Carefully remove the O- Gerotor. Be very careful to not socket head cap screws that rings you will need to reuse damage the Gerotor. -
Page 34: Warranty
FILTERS AND WATER SEPARATORS. Any PRODUCT that is in question of Warranty must be returned, shipped prepaid, to PureFlow AirDog. All Warranty claims are subject to the approval of PureFlow AirDog. If it is determined that a Warranty claim exists, PureFlow AirDog will, at its sole discretion, replace the defective PRODUCT with a comparable PRODUCT, repair the defective PRODUCT, or refund the BUYER”S purchase price in exchange for the... - Page 35 A period of 15 Calendar Days from the time of shipment is provided for the receipt of the defective unit at the PureFlow AirDog facility. Failure to return ship the defective unit to arrive within the defined time period will result in a charge of $250.00 against the customer’s credit card as the purchase cost of the defective unit.
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