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PureFlow AirDog FP-100 Installation Manual
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PureFlow AirDog FP-100 Installation Manual

For ford powerstroke 6.4l diesel engine
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INSTALLATION MANUAL
MODEL FP-100 & FP-150
With New Quick Connect Components!
FORD POWERSTROKE
6.4L DIESEL ENGINE
PLEASE READ THESE INSTRUCTIONS THOROUGHLY
BEFORE BEGINNING INSTALLATION!
PureFlow AirDog
705 MAUSOLEUM ROAD
SHELBYVILLE, IN 46176
1-877-421-3187
www.pureflowairdog.com
PROTECTED BY
CANADIAN PATENT
US PATENTS
AUSTRALIAN PATENT
2,108,391
5,355,860; 5,746,184; 6,729,310
2005101054
NEW ZEALAND PATENT
532356
Additional Foreign Patents Pending in Europe, South America, Mexico, Japan, and China!

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Summary of Contents for PureFlow AirDog FP-100

  • Page 1 INSTALLATION MANUAL MODEL FP-100 & FP-150 With New Quick Connect Components! FORD POWERSTROKE 6.4L DIESEL ENGINE PLEASE READ THESE INSTRUCTIONS THOROUGHLY BEFORE BEGINNING INSTALLATION! PureFlow AirDog 705 MAUSOLEUM ROAD SHELBYVILLE, IN 46176 1-877-421-3187 www.pureflowairdog.com PROTECTED BY CANADIAN PATENT US PATENTS...
  • Page 2 Approved for Sale and Use in California by CARB! SMALL and COMPACT 7” Long X 3.2” Wide X 10” Tall...
  • Page 3 Thus, allowing the engine “test cell” performance and efficiency, while in “real world” use. ® The AirDog FP-100 flows 100 GPH and is recommended for stock and slightly modified PowerStroke Diesels. ® The AirDog FP-150 is recommended for highly modified PowerStroke Diesels.
  • Page 4 QUICK CONNECT COMPONENT OVERVIEW Provided in this kit are two different OE style quick connection systems. These systems work together to allow for a quick, clean, and professional install. Jiffy Tite Quick Connect System Jiffy Tite’s patented quick connect system is used for the connections at the ®...
  • Page 5 Section 4…………………….………………….AirDog & Mounting Brackets Fuel Lines Section 5 A……………………………………………..……Fuel To Engine Section 5 B……………………...……….……..….……Fuel Return to Tank Section 5 C……………………..……………….….Suction line For FP-100 Section 5 D…………………………………………Suction Line For FP-150 (Includes Hi Flow Suction Tube) Electrical Harness Section 6…..…………………………………...…..…….….Electrical Harness Section 7..………….…………………….……….……….…..Final Check List...
  • Page 6 FP-100 & FP-150 Ford PowerStroke 2008 6.4L Section 2 Installation & Safety Guidelines ® AirDog MODEL FP-100 & FP-150 ® The installation of your AirDog can be made relatively easy by following the steps outlined in this manual, and: ®...

  • Page 7: Parts List

    ® AirDog FP-100 & FP-150 Ford PowerStroke 2008 6.4L Section 3 Parts List PowerStroke Parts List DESCRIPTION Part Number IMAGE Installation Manual ADI-F-100/150 FP-100 ® AirDog FP-150 ® AirDog Mounting Bracket 001-3C-0004 Mounting Hardware Kit, 901-61-0102-PM-F 010-3C-0002PC Frame Bracket 010-3C-0001PC...
  • Page 8 ILLUSTRATION OF QUICK CONNECT COMPONENTS...
  • Page 9 ® AirDog FP-100 & FP-150 Ford PowerStroke 2008 6.4L ® Section 4 AirDog & Mounting Brackets ® Installing the AirDog & Mounting Brackets the Truck’s Frame! Figure 2 Figure 3 Figure 4 4-1. Assemble the AirDog® mounting bracket to the frame bracket. Use the spacer block to adjust the AirDog®...
  • Page 10 ® AirDog FP-100 & FP-150 Ford PowerStroke 2008 6.4L ® Section 4 AirDog & Mounting Brackets ® Installing the AirDog & Mounting Brackets on the Truck’s Frame, cont’d! NOTE: You may attach the AirDog® to the bracket either before or after attaching the assembly to the frame, whichever is easier.
  • Page 11 ® AirDog FP-100 & FP-150 Ford PowerStroke 2008 6.4L Section 5-A Fuel Lines ® AirDog II Fuel Line to the Engine! 5A-1. Disconnect the fuel supply line to the engine from the OE fuel pump. This pump is located on the driver’s side inside frame rail.
  • Page 12 ® AirDog FP-100 & FP-150 Ford PowerStroke 2008 6.4L Section 5-B Fuel Lines ® Fuel Return Line from the AirDog to the Tank! Installing the fuel 'Return to Tank' assembly in Filler Tube Filler Tube Fuel Return Hose Clamp Fitting...
  • Page 13 ® AirDog FP-100 & FP-150 Ford PowerStroke 2008 6.4L Section 5-C Fuel Lines ® Section 5-C: Fuel Suction Line for AirDog FP-100! ® NOTE: The AirDog FP-150 requires a High Flow Suction Tube. If you ® are installing an AirDog...
  • Page 14 ® AirDog FP-100 & FP-150 Ford PowerStroke 2008 6.4L Section 5-D Fuel Lines ® INSTALLING THE AIRDOG FP-150 HIGH FLOW SUCTION TUBE ® The AirDog 150 includes a ½” High Flow suction tube to accommodate the high flows of this system.
  • Page 15 PureFlow AirDog ® AirDog FP-100 & FP-150 Ford PowerStroke 2008 6.4L Section 5-D High Flow Suction Tube INSTALLING THE HIGH FLOW SUCTION TUBE, C ont’d NOTE: The fuel tank used for the pictures is an example only and may not be exactly the same as your tank.
  • Page 16 ® AirDog FP-100 & FP-150 Ford PowerStroke 2008 6.4L Section 5-D High Flow Suction Tube INSTALLING THE HIGH FLOW SUCTION TUBE, C ont’d 5D-5. Measure and cut the suction tube to a length that will allow approximately 1/8” clearance off the bottom of the tank. It is suggested to form the end of the tube similar to Figure 38.
  • Page 17 ® AirDog FP-100 & FP-150 Ford PowerStroke 2008 6.4L Section 5-D High Flow Suction Tube INSTALLING THE HIGH FLOW SUCTION TUBE, C ont’d 5D-10. If the fuel tank was dropped to install the suction tube, re-install the fuel tank. If the truck bed was removed, reinstall the bed.

  • Page 18: Wiring Harness

    ® AirDog FP-100 & FP-150 Ford PowerStroke 2008 6.4L Section 6 Electrical Harness ® The AirDog is equipped with a relay controlled wiring harness. WIRING DIAGRAM (In Red) High Pressure Fuel Pump Figure 39 ® The AirDog wiring harness! AirDog® Pump Motor Lead...
  • Page 19 ® AirDog FP-100 & FP-150 Ford PowerStroke 2008 6.4L Section 6 Electrical Harness ® Connecting the AirDog Relay Control Lead Figure 42 6-3. Route the AirDog® 'Relay activation lead', the Red (+) wire with the mini fuse tap attached, to the OE fuel pump. Remove the mini fuse tap and splice the relay lead to the OE fuel pump lead.
  • Page 20 ® AirDog FP-100 & FP-150 Ford PowerStroke 2008 6.4L Section 7 Initial Startup Procedures 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.
  • Page 21 ® AirDog FP-100 & FP-150 Ford PowerStroke 2008 6.4L Section 8 Fuel Filter & Water Separator Filter Service Recommendations Plugging of either the fuel filter, the screen in the water separator nipple or the water separator itself will cause low fuel pressure and flow to the engine. Should you experience low fuel pressure, first check the screen in the water separator nipple.
  • Page 22 Section 9 AirDog® Fuel Pump Cleaning Foreign Debris from the Gearotor Assembly Step 1 Step 2 Step 3 Remove the four (4) button Carefully remove the O’ring, Remove and clean the gearotor. head cap crews that secure you will need to re-use it. Be very careful not to damage the gearotor cap.
  • Page 23 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 PRODUCT.
  • Page 24   p eriod   w ill   r esult   i n   a   c harge   o f   $ 250.00   a gainst   t he   c ustomer’s   c redit   c ard   a s   t he   p urchase     cost   o f   t he   d efective   u nit. Copyright © 2009 PFT Bulletin No. ADI-F-08P-100/150 PureFlow AirDog Printed 10 All Right Reserved Revised July 02, 2010...

This manual is also suitable for:

Fp-150