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Related Manuals for PureFlow Airdog Fuel Preporator DF-100-5G
Summary of Contents for PureFlow Airdog Fuel Preporator DF-100-5G
- Page 1 DF-100-5G DF-165-5G DF-220-5G PATENT PROTECTED: https://pureflowairdog.com/p-35853-patents.html 1994-1998 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 FITTING INSTALLATION DF-100 & DF-165 PUMP FITTING INSTALLATION DF-220 PUMP CRADLE BRACKET INSTALLATION PUMP TO FRAME INSTALLATION FUEL LINE ASSEMBLY OVERVIEW ENGINE LINE INSTALLATION RETURN LINE INSTALLATION INLET LINE DF-100 ONLY... -
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 recommendations contained herein are suggested installation guidelines only. Individual installations may vary. If any installation procedure is uncertain, contact PUREFLOW® AIRDOG for technical assistance. When installing the AirDog® fuel lines be sure to keep the ORIGINAL ENGINE RETURN LINE... -
Page 6: Parts List
PARTS LIST COMMON PARTS DESCRIPTION PART NUMBER IMAGE DF-100, DF-165, OR AirDog® II-5G DF-220 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-2-010-HD 1.75” Filler Neck Tee with Clamps 001-4A-1-0175 1/2”... - Page 7 PARTS LIST CONTINUED DF-100-5G ONLY DESCRIPTION PART NUMBER IMAGE 20ft of 1/2” Fuel Line HS20 1/2” Straight Hose Quick Connect Fitting FQC12S 3/8” Straight Straight Hose Quick Connect Fitting FQC38S 1/2” Male SAE J2044 Quick Connect x 3/4 ORB 08J2044-3/4UNF DF-165-5G ONLY DESCRIPTION PART NUMBER...
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Page 8: 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 9: Quick Connect Fitting Illustration
ILLUSTRATION OF QUICK CONNECT COMPONENTS IMAGE NOT TO SCALE VIEW OF PUMP IS LOOKING DOWN THE PORTS ARE LABELED ON THE PUMP... -
Page 10: Pump Fitting Installation Df-100 & Df-165
INSTALLING THE PUMP FITTINGS DF-100 & DF-165 TOOLS NEEDED: - Torque Wrench - 7/8” Deep Socket - 9/16” Deep Socket PARTS NEEDED: - (2) 08J2044-3/4UNF Fittings - (1) 06J2044716UNF Fitting 1a-1. Dip the threaded end of the 08J2044-3/4UNF fitting into clean motor oil and hand-thread into the “ENGINE”... -
Page 11: Pump Fitting Installation Df-220
INSTALLING THE PUMP FITTINGS DF-220 TOOLS NEEDED: - Torque Wrench - 7/8” Deep Socket - 9/16” Deep Socket -15/16” Wrench PARTS NEEDED: - (1) 08J2044-3/4UNF Fitting - (1) 06J2044716UNF Fitting - (1) 4A-1-02-10-08-S Fitting 1b-1. Dip the threaded end of the 08J2044-3/4UNF fitting into clean motor oil and hand-thread into the “ENGINE”... -
Page 12: 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 13: 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 14 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 10 using the four 5/16 bolts, lock washers, and nuts included in the mounting bracket hardware kit (figure 11).
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Page 15: 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 16: Engine Line Installation
ENGINE LINE INSTALLATION TOOLS NEEDED: - 13/16” Wrench or Extra Deep Socket - Clean Motor Oil or ATF - Hose Cutters or a way to cut Fuel Line PARTS NEEDED: - (1) WAP103 Injection Pump Fitting - (1) 1P-5-ES Sealing Washer - (1) FQC1290 1/2”... - Page 17 ENGINE LINE INSTALLATION CONTINUED 5-3. Assemble one end of the hose (Reference section 4) using Fuel line end FQC1290 and plug it into the WAP103 fitting installed in the previous step. A “click” will be heard once the fitting is properly connected. FQC1290 HS20 DF-100 &...
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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-1-0175 1.75” Filler Neck Return Tee with Clamps - (1) FQC3890 3/8“ 90deg Quick Connect Fitting - (1) FQC12S 1/2”... -
Page 19: Inlet Line Df-100 Only
INLET LINE INSTALLATION DF-100 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 DF-100 CONTINUED 7-3. 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 Df-165 Only
INLET LINE INSTALLATION DF-165 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 DF-165 CONTINUED The DF-165 and DF-220 REQUIRE the installation of this high flow suction tube or aftermarket sump! Failure to do so WILL cause pump failure and may void your warranty! 8-2. To install the WAP109, you will need to either drop the fuel tank or remove the truck bed.
- Page 23 INLET LINE INSTALLATION DF-165 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 DF-165 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. 8-3. Once either the tank has been dropped or the bed removed, remove the collection basket as shown in figures 35 and 36 using a hammer and large screwdriver to remove the retaining ring.
- Page 25 INLET LINE INSTALLATION DF-165 CONTINUED 8-5. 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 39 8-6. Mock the suction tube in the fuel tank and measure from the top of the fuel tank to the bottom of the green seal (Figure 40).
- Page 26 INLET LINE INSTALLATION DF-165 CONTINUED 8-7. Drill crossing pilot holes through the nylon tube, centered on the marked line, as shown (Figure 42). Use a larger bit (1/2” MAX) to open the holes up (Figure 43). Figure 42 Figure 43 8-8.
- Page 27 INLET LINE INSTALLATION DF-165 CONTINUED 8-10. 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. The factory engine return line MUST be reconnected to the fuel module! The factory engine feed port can be capped off with a vacuum cap.
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Page 28: Inlet Line Df-220 Only
INLET LINE INSTALLATION DF-220 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 - 1“... - Page 29 INLET LINE INSTALLATION DF-220 CONTINUED 9-4. Follow steps 8-6 to 8-10 9-5. Run the fuel line along the frame as mentioned in step 4-3 to Suction Tube (WAP109). Cut the fuel line HS5807 to length and insert fuel line end 4A-1-09-10-10-B per step 4-1.
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Page 30: Tie The Injector Return To The Engine Return
TIE THE INJECTOR RETURN TO THE ENGINE RETURN TOOLS NEEDED: - 3/4” or 19mm Wrench - 9/16 or 14mm Wrench - 17mm Wrench - 19mm Wrench - 10mm Wrench PARTS NEEDED: - (2) 4A-1-18-05-04 5/16” Push Lock x 1/4” Male NPT - (1) 001-4A-1-0008 Injection Pump Return Tee - (1) 4C-1-02-05-0001 PPump Return Fuel Line Fuel is returned from the P-7100 fuel pump and also from the... - Page 31 TIE THE INJECTOR RETURN TO THE ENGINE RETURN CONTINUED 10-2. Remove the inlet banjo fitting from the fuel filter housing using an 17mm wrench. The Inlet line can bemoved out of the way for now. Figure 61 10-3. Remove the Fuel Filter Head From the truck by removing the two 10mm hex bolts.
- Page 32 TIE THE INJECTOR RETURN TO THE ENGINE RETURN CONTINUED 10-6. There is enough 5/16” fuel line in this kit to replace the factory rubber fuel line if it is damaged, or you can cut a section of the fuel return line P/N 4C-1-02-05-001 to length.
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Page 33: Factory Fuel Pump Removal
FACTORY FUEL PUMP REMOVAL TOOLS NEEDED: - 10mm Wrench or Socket The Mechanical Fuel Pump on the side of the engine MUST be either disabled or completely removed! THIS STEP CAN NOT BE SKIPPED! 11-1. The engine mounted mechanical fuel pump can be disabled by removing the plunger from the pump that rides on the cam. -
Page 34: Wiring Installation
WIRING INSTALLATION MINI-TAP RELAY TRIGGER LEAD AirDog® MOTOR LEAD FUSE HOLDER RELAY WITH 20A FUSE BATTERY NEGATIVE LEAD BATTERY POSITIVE LEAD Figure 71 12-1. Secure the relay and fuse holder to the vehicle. Be sure to route the wires away from any moving parts. - Page 35 WIRING INSTALLATION CONTINUED 12-2. Route the red relay trigger wire, with the mini fuse tap attached, to the fuse panel. Connect it to a terminal that is hot when key on. Install the fuse that was removed to install the fuse tap into the open slot in the fuse tap before it is installed.
- Page 36 WIRING INSTALLATION CONTINUED 12-4. 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 75...
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Page 37: 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. 13-1. Fill the water separator with clean diesel fuel. 13-2. Turn the starter key to the on/run position. 13-3. -
Page 38: 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 39: Gerotor Pump Service
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 40: Adjusting Fuel Pressure
ADJUSTING FUEL PRESSURE AirDog®II-5G ADJUSTABLE FUEL PRESSURE REGULATOR The AirDog®II-5G rises to a new level of performance with an adjustable diaphragm fuel pressure regulator. This regulator offers more consistent fuel pressure and allows for higher flow rates at pressure. This regulator can also be boost compensated to battle any pressure drops under wide open throttle. -
Page 41: 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 42 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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