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INSTALLATION MANUAL DF-100 & 150 w/Preset Regulator DF-165 w/Adjustable Regulator

CUMMINS POWERED

DODGE TRUCKS Model Year 1998 ½ THROUGH 2004 High Performance Fuel System

PLEASE READ THESE INSTRUCTIONS THOROUGHLY BEFORE BEGINNING INSTALLATION!

1412 CREEK TRAIL DRIVE JEFFERSON CITY, MO 65109

573 635-0555 VOICE 573 635-0778 FAX

www.pureflowtechnologies.com

CANADIAN PATENT 2,108,391

PROTECTED BY US PATENTS 5,355,860; 5,746,184; 6,729,310

AUSTRALIAN PATENT 2005101054

NEW ZEALAND PATENT 532356 Additional Foreign Patents Pending in Europe, South America, Mexico, Japan, and China!


Approved for Sale and Use in California by CARB! (Limited Edition Model Pictured)

SMALL RETURN LINE FOR AIR, VAPOR AND FOAM

PRESET OR ADJUSTABLE PRESSURE REGULATOR

DEMAND FLOW SERIES FLOWS ONLY THE AMOUNT OF FUEL THE ENGINE REQUIRES

SMALL and COMPACT

7” Long X 3.2” Wide X 10” Tall LIFETIME LIMITED EXPRESS WARRANTY NOTICE! To register your LifeTime Limited Express Warranty, you must fill out and return the enclosed Product Registration/Warranty card with a copy of the original sales receipt to PureFlow ® Technologies Within Thirty Days of

Purchase. Failure to fill out and return your Registration/Warranty card with a copy of the original sales receipt within Thirty Days will result in your receiving a ONE YEAR WARRANTY!

2


PureFlow® Technologies High Flow Fuel Module Upgrade! Converts your stock Fuel Module to a High Flow System! Large -8 JIC Bulkhead Fitting For Fuel Supply! Line!

AirDog®II Return Line Connects to Original Fuel Module Suction Tube!

Large ½” ID OE Style Flex Tube!

AirDog®II Returns Directly Into the Collection Basket

Injector Line Clamps!

Stainless Steel Suction Tube!

Suction Tube Mounting Block w/Set Screw! By passes In-Tank Fuel Pump!

NO MORE Quarter Tank fuel Problems! NO More Drilling Holes in Your Fuel Tank to Install an Aftermarket Draw Straw! 3


OVERVIEW Welcome to PureFlow® Technology’s AirDog®II Fuel Air Separation, Filtration and Delivery System for the Diesel Engine The AirDog®II Fuel Preporator®, the Original Fuel Air Separation System, is a premium replacement fuel pump ad complete filtration system for the Dodge Cummins Diesel Engine. The system removes water, particulates and entrained air from the fuel. The entrained air that is separated from the fuel is returned to the tank through a small return line. The fuel is delivered to the engine at the correct pressure flow to meet the demands of the engine under all operating conditions. The AirDog®II DF-100 & DF-150 feature a Preset Pressure Regulator. The AirDog®II DF-165 features an Adjustable Pressure Regulator. All AirDog® systems included a complete installation kit. The AirDog®II DF-100 is recommended for stock and slightly modified 5.9L Cummins Diesels. The AirDog®II DF-150 and DF-165 Adj. are recommended for highly modified 5.9L Cummins Diesels.

PureFlow® products are manufactured with a personal touch, unsurpassed attention to detail and the most stringent Quality Assurance! TYPICAL INSTALLATION LAYOUT

Figure 1

The AirDog®II draws fuel from the fuel tank at constant flow, removing water, particulates, and air/vapor. A regulated pressurized flow is maintained to meet the engine’s varying fuel demands. The separated air/vapor and excess fuel not needed by the engine are returned from the AirDog®II to the fuel tank.

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AirDog®II Demand Flow

PureFlow® Technologies, Inc Dodge 1998 ½ - 2004 Table of Contents

Section 1

TABLE OF CONTENTS Section 1……………………………….…………………..Table of Contents Section 2…………………………………Installation and Safety Guidelines Section 3……………………………….…………………………….Parts List

INSTALLATION PROCEDURES Section 4…………………….……………… AirDog® & Mounting Brackets

Fuel Lines Section 5 A…………………………..………1998.5-’02 AirDog® To VP-44 Section 5 B………………………………………..2003-’04 AirDog® to CP3 Section 5 C………………………………………...Fuel Module Modification Section 5 D……………………...……….………………Fuel Return to Tank Section 5 E……………………...…………………Fuel Supply to AirDog®II

Electrical Harness Section 6…..……………………………………………….Electrical Harness Section 7..………….…………………….…………………..Final Check List

Maintenance & Up Grades Section 8…………………………….……Filter Service Recommendations Section 9...…………………….…………...Cleaning the Gerotor Assembly Section 10………………………………………..…The Pressure Regulator

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AirDog®II Demand Flow

PureFlow® Technologies, Inc Dodge 1998 ½ - 2004 Installation & Safety Guidelines

Section 2

AirDog®II MODEL FP-100, 150, & 165 ADJ.

The installation of your AirDog®II can be made relatively easy by following the steps outlined in this manual, and: 1.

Inventory the package components completely. Notify PUREFLOW® TECHNOLOGIES, INC. immediately of any parts missing or damaged.

2.

Read the installation manual completely. Understand how the system operates and installation recommendations before beginning installation.

3.

The installation recommendations contained herein are suggested installation guidelines only. Individual installations may vary.

4.

Use diesel fuel compatible thread sealer on all NPT tapered pipe thread fuel fitting connections!

If any installation procedure is uncertain, contact PUREFLOW® TECHNOLOGIES, INC for technical assistance.

SAFETY GUIDELINES! WARNING!

Please be sure to chock the vehicle’s tires to prevent rolling.

WARNING!

Please use proper supports when working beneath an elevated vehicle.

WARNING!

Most diesel pickups have two (2) 12volt batteries. Disconnect the battery cables to both batteries before proceeding with the AirDog®II installation.

IMPORTANT!

Vehicle frame rails should not be drilled into or welded upon.

CAUTION!

Wear safety glasses when operating power tools such as drills and grinders or when using a punch or chisel.

CAUTION!

Use common sense when routing fuel lines and electrical harnesses. Keep them away from hot exhaust components and/or moving parts. Properly secure lines to prevent chaffing.

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AirDog®II Demand Flow Section 3 QTY

PureFlow® Technologies, Inc

AirDog® Parts List

DESCRIPTION

1

Installation Manual

1

AirDog®II

1

AirDog®II Mounting Bracket

1

Mounting Bracket Hardware Kit, Includes:

Part Number ADI-D-9802P-100/150 DF-100 Preset DF-150 Preset DF-165 Adj. 001-3C-0004

4 Socket Head Cap Screws, 1/4-20 x 1-1/4" Lg. 4 Lock Washers, 1/4” 4 Hex Nuts, 1/4-20

1

Frame Bracket

1

Frame Bracket Hardware Kit, Includes:

901-61-0101-PM 010-3C-0002PC 010-3C-0001PC (Included In)

3ea 3/8” x 4-1/2” Hex Head Bolt, 3ea 3/8” Nut 3ea 3/8” Lock Washer 1

1

901-61-0101-PM 010-3C-0003A

Spacer Spacer Bracket Hardware Kit, Includes:

(Included In)

4ea Bolts 5/16”x 2 ¾” L 4ea Washers 4ea Nuts

1

Dodge 1998 ½ - 2004 Parts List

901-61-0101-PM 5E-2-011

Wiring Harness

12 Ft. 9 Ft

½” Fuel Line 1/4” Fuel Return Line

4C-1-02-08-002 4C-02-04-001

1

Bundle of Plastic Ties

5H-2-1-06/12

2 1

-8 JIC x 3/8” NPT -4 JIC x 1/8” NPT

1

3/8” Quick Connect x ¼” Hose Barb (PureFlow® Brand)

1

-4 JIC Swivel x ¼” Hose Barb

3

-8 Swivel x ½” Push Lock

4A-1-09-08-08-B

1

-8 Swivel x ½” Push Lock 90o

4A-2-03-08-08-S

1 1

12mm x -8 JIC w/O-ring Fuel Module Up Grade Kit

001-4A-1-0002-S 901-01-0500

4A-1-02-08-06-S 4A-1-01-04-02-S 4A-1-17-A-01-AN 4A-1-01-04-04-B

7

IMAGE


AirDog®II Demand Flow

PureFlow® Technologies, Inc Dodge 1998 ½ - 2004 AirDog II & Mounting Brackets ®

Section 4

Installing the AirDog®II & Mounting Brackets on the Truck’s Frame!

Figure 2 4-1.

Figure 3

Assemble the AirDog®II mounting bracket to the frame bracket.

Figure 4

Figure 5

4-2.

Use the aluminum spacer block as necessary to clear lines and wiring harnesses on the frame. Adjust the assembly up or down on the frame bracket as necessary for clearance.

4-3.

Apply the LOCTITE diesel fuel compatible thread sealer to the-8 fitting 3/8” NPT threads. The thread sealer is packed in the Fuel Module Up-Grade Kit. FUEL IN ENGINE

Figure 6 Figure 7 4-4.

Install the 3/8” NPT x -8 JIC flare fitting in the ‘FUEL IN’ and the out to ‘ENGINE’ ports in the AirDog®II

4-5.

Install the 1/8” NPT x -4 JIC return fitting into the port next to the “Out to Engine” port. Apply thread sealer to the NPT threads.

Figure 8 Figure 9 4-6.

Attach the AirDog®II to the frame bracket assembly.

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AirDog®II Demand Flow

PureFlow® Technologies, Inc

Section 4

Dodge 1998 ½ - 2004 AirDog II & Mounting Brackets ®

Installing the AirDog® & Mounting Brackets on the Truck’s Frame, cont’d!

NOTE: The AirDog®II can be mounted on either the inside or the outside of the frame, as space or personal choice dictates. Mount The AIRDOG®II Outside The Frame

Or

Figure 10

Figure 11

Inside The Frame

Figure 12

Figure 13

For this installation, the AirDog®II is mounted inside the frame! 4-7.

4-8.

Clamp the frame between the AirDog®II bracket assembly and the backing plate using the 3/8” x 4 ½” bolts, lock washers, and nuts included in the kit.

®

Figure 14

Position the AirDog II on the frame as necessary for clearance. Properly torque!

NOTE: Be sure to mount the AirDog®II so the ‘FUEL IN’ port is directed toward the rear of the vehicle. Figure 15 Figure 16 NOTE: Some pickup model frame rails have a bracket that is only used to support the frame during the manufacturing process If this bracket is on your frame rail and obstructs the proper positioning of the mounting bracket, you may remove part or all of it, as needed. Be very careful not to damage the frame flange! 9


AirDog®II Demand Flow

PureFlow® Technologies, Inc Dodge 1998 ½ - 2004 Fuel Lines

Section 5 A

This section is for the 1998.5 – 2002 Dodge Fuel Supply Line from the AirDog®II to the VP-44 The AirDog®II fuel filter is made by Fleetguard and has a 2 micron Stratapore™ media. When installing the AirDog®II fuel system it is recommended to bypass the factory filter canister. 5A-1. Remove the “banjo bolt” and the original factory fuel supply line at the fuel inlet port of the VP44 injector pump (Ref. Figure 14).

Caution: Do not over torque the 12mm fitting.

It may break! Figure 17

Figure 18

5A-2. Install the 12mm x -8 flare fitting with the O-ring supplied into the inlet port of the VP-44 (Ref. Figure 17) vacated by the original banjo fitting. Properly torque the 12mm x -8 flare fitting. Be careful not to over torque and break the fitting! 5A-3. Measure and cut the length of line required to connect the 'Fuel to Engine' port on the AirDog®II to the 12mm x -8 flare fuel inlet fitting on VP-44. 5A-4. Install a straight -8 Swivel x 1/2" Push Lock on the end of the fuel line connecting to the AirDog®II and a 90o -8 Swivel x 1/2" Push Lock on the end connecting to the VP44 injection pump.

Figure 19

Figure 20

Figure 21

5A-5. Connect the end of the fuel line with the straight -8 fitting to the fitting on the AirDog®II port marked “ENGINE”. Properly torque the fitting. AirDog®II Fuel Line to VP-44

Figure 22 10


AirDog®II Demand Flow

PureFlow® Technologies, Inc Dodge 1998 ½ - 2004 Fuel Lines

Section 5 A

Fuel Supply Line from the AirDog®II to the VP-44! 5A-6. Route and connect the other end of the fuel line with the 90o fitting to the fuel inlet fitting just installed on the VP-44. When tightening the swivel fitting, use a back up wrench to prevent breaking the 12 mm fitting.

Figure 23 NOTE: It is NOT NECESSARY or recommended to keep the factory filter canister in the system. You may either plug the inlet and outlet ports of the bypassed filter canister or remove the housing completely.

Figure 24

SECTION 5B: Fuel Supply Line from the AirDog®II to the CP-3 This section is for the 2003 – 2004 Dodge The AirDog®II fuel filter is made by Fleetguard and is available in 2 micron Stratapore™ media. When installing the AirDog®II fuel system it is recommended to bypass the factory filter canister. 5B-1. Remove the “banjo bolt” and the original factory fuel supply line at the fuel inlet port of the CP-3 high pressure pump.

Figure 25

Figure 26

5B-2. Install the 12mm x -8 flare fitting with the O-ring supplied into the inlet port of the CP-3 vacated by the original banjo fitting. Properly torque the 12mm x -8 flare fitting. Caution: Do not over torque the 12mm fitting, IT MAY BREAK! 11


AirDog®II Demand Flow

PureFlow® Technologies, Inc Dodge 1998 ½ - 2004 Fuel Lines

Section 5 B

Fuel Supply Line from the AirDog®II to the CP-3, cont’d

5B-3. Measure and cut the length of line required to connect the 'Fuel to Engine' port on the AirDog®II to the 12mm x -8 flare fuel inlet fitting on CP-3. CP-3 Fuel Supply Line AirDog®II Fuel Line to Engine

Figure 27 Figure 28 5B-4. Install a 90o -8 Swivel x 1/2" Push Lock on the end of the fuel line to the engine and a straight -8 Swivel x 1/2" Push Lock on the end to the AirDog®II.

Figure 29

Figure 30

Figure 31

5B-5. Connect the end of the fuel line with the straight -8 fitting to the fitting on the AirDog®II port marked “ENGINE”. Properly torque the fitting. To “ENGINE”

Figure 32 5B-6. Route and connect the other end of the fuel line with the 90o fitting to the fuel inlet fitting just installed on the CP-3. When tightening the swivel, use a back up wrench on the 8mm fitting to preventing breaking it.

Figure 33 NOTE: It is NOT NECESSARY or recommended to keep the factory filter canister in the system. This will cause additional flow restriction to the CP-3. It is suggested to cap or plug the inlet port to the OE fuel pump and outlet port of the bypassed filter canister.

Figure 34 12


AirDog®II Demand Flow

PureFlow® Technologies, Inc Dodge 1998 ½ - 2004 High Flow Fuel Module

Section 5 C

Overview

The AirDog®II Fuel Module High Flow Upgrade! The OE fuel tank location in most pickup trucks is generally along the inside of the driver’s side frame rail. With space between the frame rail and drive shaft limited, the fuel tank must be narrow to fit and have clearance away from the drive shaft. Consequently, to contain the volume of fuel required, the fuel tank must be quite long. With vehicle acceleration and/or deceleration waves and sloshing develop which can cause a fuel suction tube to ‘suck air’. To overcome this problem, the vehicle manufacturers incorporate the use of a fuel module with a collection basket.

Fuel Tank

Low Fuel Level

Waves Fuel Module (Collection Basket)

Suction Tube (Draw Straw)

Figure 35 When the fuel level is low, the collection basket catches fuel as it flows back and forth. Containing fuel in the basket ensures that the engine will always have a fuel supply. However, once the fuel level drops below the top of the collection basket, the high flow of a High Performance Fuel System will drain fuel more quickly than it enters. This will eventually empty the basket and starve the engine of fuel causing the engine to die. Additionally, the suction lines of the stock collection basket are too small to handle the higher flows without cavitating.

The AirDog®II Fuel Module Upgrade The AirDog®II Fuel Module Upgrade Kit for the OE fuel module overcomes the issues discussed above. With this fuel module modification, the AirDog®II can draw directly from the fuel module without problems. The Fuel Module Upgrade Kit has all of the components necessary to convert the stock fuel module into a high flow system. 13


AirDog®II Demand Flow

PureFlow® Technologies, Inc Dodge 1998 ½ - 2004 High Flow Fuel Module

Section 5 C

The AirDog®II Fuel Module Upgrade Kit Includes:  1 set. Bulkhead Fitting, Sealing Washers, & Lock Nut

 1 ea. -8 JIC Flare x 3/8” NPT

 2 ea. Injector Line Clamps

 1 ea. OE Style Flexible Fuel Line with ½” ID

 1 ea. Stainless Steel Suction Tube ½” ID

 1 Tube Locktite® Sealer

 1 ea. Mounting Block & Stainless Steel Set Screw

 3 ea. Tie Straps

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AirDog®II Demand Flow

PureFlow® Technologies, Inc Dodge 1998 ½ - 2004 High Flow Fuel Module

Section 5 C

INSTALLING THE AIRDOG®II FUEL MODULE UPGRADE! To access the fuel tank to install the Up Grade Kit, it is necessary to either drop the fuel tank or to lift the truck bed. Should you choose to pull the pickup bed to access the fuel 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. CAUTION: If you are unsure of the proper procedure for removing the fuel tank or truck bed from the vehicle, consult your vehicle manufacturer’s service manuals for detailed instructions.

When Dropping the Tank, Always Remember Safety First! Figure 36

Figure 37

Figure 38

If you choose to remove the bed, properly support the truck bed to prevent serious injury or death!

Figure 39

Figure 40

15


AirDog®II Demand Flow

PureFlow® Technologies, Inc Dodge 1998 ½ - 2004 High Flow Fuel Module

Section 5 C

INSTALLING THE AIRDOG®II FUEL MODULE UPGRADE! CONTINUED NOTE: The fuel tank used for the pictures is an example only and may not be exactly the same as your tank.

After the fuel tank has been accessed: 5C-1. Thoroughly clean the area at the top of the fuel tank around the fuel tank module, the lock nut and lock nut threads. Disconnect the electrical connector, the fuel supply and return lines. Remove the fuel module.

Figure 41 Figure 42

5C-2. Drill a 9/16 hole in the top of the Fuel Module.

Figure 43

Figure 44 5C-3. Install the -8 JIC x 3/8” NPT fitting in the bulkhead fitting

Figure 45

Figure 46 5C-4. Insert the bulkhead fitting with the washer, gasket side down, into the 9/16” hole. 16


AirDog®II Demand Flow

PureFlow® Technologies, Inc Dodge 1998 ½ - 2004 High Flow Fuel Module

Section 5 C

INSTALLING THE AIRDOG®II FUEL MODULE UPGRADE! CONTINUED 5C-5. Install the sealing washer and lock nut on the bulkhead fitting and tighten.

Figure 47

Figure 48

5C-6. Apply sealer to the ½” flex tube and bulkhead fitting.

Figure 49 5C-7. Install the flex tube and clamp on the bulkhead fitting. Properly tighten the clamp. 5C-8. Place the ‘Suction Tube Block’ on the basket wall and mark the location for the set screw hole.

Figure 50 5C-9. Remove the ‘Suction Tube Block’ and drill a 3/16” hole in the location marked for the set screw.

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AirDog®II Demand Flow

PureFlow® Technologies, Inc Dodge 1998 ½ - 2004 High Flow Fuel Module

Section 5 C

INSTALLING THE AIRDOG®II FUEL MODULE UPGRADE! CONTINUED 5C-10. Place the ‘Suction Tube Block’ back on the fuel module basket and insert the suction tube into the block.

Figure 51

Figure 52 5C-11. Be careful to rotate the suction tube so the tab on the end is positioned to hold the tube off the bottom to prevent blockage. Assemble and tighten the set screw.

FIGURE 53

FIGURE 54

5C-12. Apply Loctite sealer to the suction tube, and install the flex tube and clamp.

FIGURE 55

FIGURE 56

5C-13. Cut the original suction tube off just above the connector and secure with the two tie straps as shown. The original suction tube is now the AirDog®II air/vapor return line.

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AirDog®II Demand Flow

PureFlow® Technologies, Inc Dodge 1998 ½ - 2004 High Flow Fuel Module

Section 5 C

INSTALLING THE AIRDOG®II FUEL MODULE UPGRADE! CONTINUED 5C-14. Re-install the modified fuel module in the fuel tank. Be careful to not bend the sending unit float arm when re-installing the fuel module. 5C-15. Re-install the fuel tank in the truck. Do not completely “button up” the tank straps until all of the new fuel lines as well as the original engine return line and electrical connector have been re-connected to their respective fittings on the fuel module.

SECTION 5D: Air/Vapor Return Line from the AirDog® to the Fuel Module

5D-1.

Measure and cut the length of ¼” fuel line necessary to connect the AirDog®II return port to the fuel module “suction tube’ which is now modified internally to be the AirDog®II air/vapor return. Return Line to Tank

Figure 57

5D-2. Install the PureFlow® ¼” hose barb x 3/8” quick connect fitting on one end of the ¼” fuel return line.

Figure 58 5D-3. Install a ¼” hose barb x -4 JIC swivel on the other end of the fuel line. 5D-4 Connect the end of the Air/Vapor return line with the -4swivel to the -4 JIC fitting on the AirDog® port marked “TANK”.

Figure 59 Figure 60 AirDog® Return to Tank Fuel Module Air/Vapor Return 5D-5. Connect' the end with the 3/8” quick connect fitting to the return tube on the fuel module. Be sure to snap the RETAINER CLIP into place! 19


AirDog®II Demand Flow

PureFlow® Technologies, Inc Dodge 1998 ½ - 2004 Fuel Lines ®

Section 5 E

Fuel Suction Line for AirDog II

5E-1. Measure and cut the length of fuel line required to connect the Fuel Module “SUCTION TUBE” to the AirDog®II fuel inlet port marked "Fuel In".

Figure 61

Figure 62

5E-2. Install a straight -8 swivel x 1/2" Push Lock into each end of the fuel line. .

Lubricate the barb end of the Push Lock fitting with oil.

Push the fuel line completely onto the barb end of the fitting.

Figure 63

Figure 64

5E-3. Connect the straight -8 swivel to the -8 flare fitting on the AirDog® “Fuel In” port. Torque the fittings.

Figure 65 Figure 66 5E-4. Route the other end of the fuel suction line to the fuel tank suction tube.

Figure 67 PureFlow® 3/8 quick connect fitting features TWO O-rings for better sealing! th

20


AirDog®II Demand Flow

PureFlow® Technologies, Inc Dodge 1998 ½ - 2004 Electrical Harness

Section 6

The AirDog®II wiring harness features all water proof Deutsch connectors, relay, and fuse holder. When properly installed, the AirDog®II is controlled by the engine’s ECM. WIRING DIAGRAM (In Red)

Figure 68 The AirDog®II is activated by the ECM through a relay controlled wiring harness connecting directly to the original ECM Deutsch pump connector.

Figure 69 CAUTION: If the OPTIONAL Low Pressure Indicator Light is not used, be sure to insulate the two (2) #10 Indicator Light connectors to prevent accidental contact.

Securing the Relay and Fuse Holder to the Vehicle 6-1.

Secure the relay and fuse holder to the vehicle.

Figure 70

Figure 71 21


AirDog®II Demand Flow

PureFlow® Technologies, Inc Dodge 1998 ½ - 2004 Electrical Harness

Section 6

Connecting the AirDog®II Relay Control to the ECM 6-2.

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.

Figure 72 Figure 73

6-3.

Carefully route and connect the AirDog®II relay lead, the Grey Deutsch two pin connector on the AirDog®II wiring harness, to the ECM pump lead.

NOTE: The power supply leads can be connected to the battery or the alternator. Connecting the power supply leads to the alternator instead of the battery will create a corrosion free connection. Black (-) 6-4A. Route the Red & Black power supply leads to the alternator. Connect the Black (-) lead to the alternator Chassis Ground connection. Connect the Red (+) lead to the alternator Hot Lead going to the battery.

Figure 74

OR 6-4B. Should you choose to connect the power supply leads directly to the battery, connect the RED (+) lead to the POSITIVE (+) post of the driver's side battery. Connect the BLACK (-) lead to the NEGATIVE (-) post of the same battery.

Figure 75 6-5.

Route the wiring harness to the AirDog®II and connect the 2 pin Deutsch connector to the corresponding connector on the AirDog®II.

Figure 76 22

Red (+)


AirDog®II Demand Flow

PureFlow® Technologies, Inc Dodge 1998 ½ - 2004 Electrical Harness

Section 6

INSTALLING THE OPTIONAL LOW PRESSURE INDICATOR LIGHT 6-6.

Remove the 1/8” npt plug located in the top of the base below the end of the motor. Screw the 45o adaptor fitting and pressure switch into this port and tighten. Connect the two pin connector on the wiring harness to the pressure switch.

Optional Low Fuel Pressure Warning Light!

Figure 77 6-7.

Figure 78

Select a suitable location to install the Indicator Light! Drill an 11/16" hole at that location. Drill a 5/8" hole in firewall to allow entry of the Indicator Light harness into the passenger compartment.

6-8.

Route the Indicator Light harness through the firewall. Install the grommet supplied with the kit around the wiring harness where it passes through the firewall to prevent chaffing.

6-9.

Install the Indicator Light and Dash Plate in the location you chose. Install the adhesive backed dash plate by removing the backing and matching the corresponding dash plate hole with the 11/16" hole.

6-10. Properly assemble the Indicator Light in the dash plate. Connect the two connectors on the wiring harness to the spade connectors on the indicator light. BE SURE TO PROPERLY ROUTE AND SECURE THE WIRING HARNESS TO THE VEHICLE.

LIFETIME LIMITED EXPRESS WARRANTY NOTICE! To register your LifeTime Limited Express Warranty, you must fill out and return the enclosed Product Registration/Warranty card with a copy of the original sales receipt to PureFlow ® Technologies Within Thirty Days of

Purchase. Failure to fill out and return your Registration/Warranty card with a copy of the original sales receipt within Thirty Days will result in your receiving a ONE YEAR WARRANTY! 23


AirDog®II Demand Flow

PureFlow® Technologies, Inc Dodge 1998 ½ - 2004 Initial Startup Procedures

Section 7

INITIAL START PROCEDURE The AirDog®II 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. 7-1.

Pre-fill the water separator with diesel fuel.

7-2.

Turn the starter key to the on/run position. Note: It may be necessary to momentarily engage the starter in order for the ECM to energize the AirDog®II.

7-3.

While the AirDog®II is operating, bleed the fuel line to the engine of air by loosening the fuel line connection at the engine fitting. As soon as the line is purged of air and pure fuel is observed, properly tighten the fuel fitting. NOTE: put a rag or shop towel over and around fitting to prevent splatter. Catch all spilled fuel and dispose of properly.

7-4.

Start engine!

RECHECK ALL FUEL FITTINGS FOR LEAKAGE AND PROPERLY TORQUE. BE SURE ALL FUEL LINES ARE PROPERLY ROUTED TO PROTECT FROM EXCESSIVE HEAT AND SECURED TO PROTECT FROM CHAFFING AND ABRASION. RECHECK ALL ELECTRICAL LINES, SECURE AS NECESSARY.

Checking Pump Noise! Note: Each AirDog®II has been manufactured in a Quality Controlled process and wet tested for operation and performance before shipment. This is a very quiet and smooth running system. With fuel or air alone, the AirDog®II fuel pump will run very quietly. However, if any fuel fitting on the vacuum side, between the fuel tank and the AirDog®II or the water separator, has been left loose during the installation process, the system may suck air at an excessive rate and will be very noisy. Additionally, should the suction line be pinched or restricted, cavitation can cause vapor to form. To check for this problem, unscrew the water separator 3 or 4 full turns and activate the AirDog®II by turning the ignition switch to on. If the AirDog®II runs quietly, then excessive air from a loose fitting, leaking water separator seal or vapor caused by restriction and a high vacuum is most likely the reason for the excessive noise. Correct as necessary. A.

The seal groove in the 3” filter is a snug fit and on occasion the seal has been found to not be fully seated. Remove the water separator; remove the seal from the top of the nut plate. Clean and lubricate the seal grove. Carefully replace the seal in the grove. Be sure to fully seat the seal.

B.

Check all fittings, especially the quick connect at the tank.

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AirDog®II Demand Flow

PureFlow® Technologies, Inc Dodge 1998 ½ - 2004 Fuel Filter & Pre-filter

Section 8

Filter Service Recommendations Plugging of either the fuel filter or water separator will cause low fuel pressure and flow to the engine. Should you experience low pressure, first check the pre-filter for plugging and restriction? If the low fuel pressure issue continues, replace the fuel filter.

AirDog®II 2 Micron Stratapore™ Fuel Filter

AirDog®II Wire Screen Pre-filter

Drain Valve Limited Edition Model Shown

Figure 79 The Pre-filter The AirDog®II wire screen water separator pre-filter is serviceable and does not need to be replaced as does the fuel filter. Replace the water separator only if it should become damaged or defective. Servicing of the water separator simply requires draining at regular intervals. It is suggested to check/drain the water separator every three months or as needed should you experience excessive ‘water in fuel’ conditions. When reinstalling the water separator, be sure to clean the under side of the AirDog®II base. Follow the instructions printed on the water separator for proper tightening procedures.

Caution: Be extremely careful to prevent any contaminates or debris from entering the water separator should it become necessary to remove it for cleaning! Large debris will jam the Gerotor and cause the fuse to blow. This is not a warranty item. Should this happen, it is easily put back into working order. See the instructions on “How to R & R the Gerotor” for proper procedures. The Fuel Filter Remove the fuel filter by turning it counter clockwise. Do Not pre-fill the fuel filter with fuel. The AirDog®II will fill the filter and prime the system automatically. Follow the instructions on the filter for proper tightening procedures. CAUTION: Dispose of waste fuel and used filters properly to protect OUR environment! 25


AirDog®II Demand Flow

PureFlow® Technologies, Inc Dodge 1998 ½ - 2004 Cleaning the Gerotor Assembly

Section 9

Cleaning Foreign Debris from the Gerotor Assembly Step 1 Remove the four (4) buttons head cap crews that secure the Gerotor cap.

Step 4 Clean the inside of the Gerotor pocket.

Step 2 Step 3 Carefully remove the O-ring, Remove and clean the Gerotor. you will need to re-use it. Be very careful not to damage the Gerotor.

Step 5 Replace the O-ring and center gear.

Step 7 Install the Gerotor cap. Be very careful to index the cap to position the wide space between the half moon cuts to the bottom.

Step 6 Align the teeth and install the outer gear.

Step 8 Replace the cap into position. Be very careful, do not pinch the O-ring. Torque the cap screws. in an opposing pattern. 1.

4.

3.

2.

NOTE: Should any installation problems arise, please call, toll free 1-877-463-4373 or 573-635-0555, for assistance (Monday – Friday, 8:00 am – 5:00 pm CST). 26


AirDog®II Demand Flow

PureFlow® Technologies, Inc Dodge 1998.5 - 2004 Pressure Regulator

Section 10

AirDog®II DF-165 with Adjustable Pressure Regulator! The AirDog®II rises to a new level of excellence with an ALL NEW Adjustable Regulator machined from stainless steel with a double O-ring seal system and a soft seat piston.

Original AirDog® “Ball and Spring” Regulator

ALL NEW Adjustable Regulator w/ all Stainless Steel Components and Soft Seat Piston

Changing the Regulator Spring Step 1. Remove the regulator by” turning the “Base Nut/Adjustor Body counter clockwise. Step 2. After removing the regulator assembly, slide the piston from the regulator assembly and remove the spring. Step 3. Slide the new spring into position, replace the piston. Step 4. Replace the assembly in the base. Tighten the Base Nut to proper torque. PRESSURE ADJUSTMENT

To adjust the AirDog®II regulator, loosen the jam nut and turn the adjustor screw counter clockwise to reduce the output pressure or clock wise to increase the pressure.

Non-adjustable regulator used in the AirDog®II DF-100 & 150 Preset system. Stainless Steel components with a Double O-ring Seal System and Soft Seat Piston. 27


Copyright Š 2009 PureFlow Technologies, Inc. All Right Reserved

PFT Bulletin No. ADII-DF98.504 Printed 09 Revised March 3, 2009

28

Air Dog INSTALL Manual fp100 &150 Preset RegulatorDF-165 w/Adjustable Regulator 1998.5- 2004 Cummins  

Air Dog INSTALLATION MANUAL DF-100 & 150 w/Preset RegulatorDF-165 w/Adjustable Regulator CUMMINS POWERED 1998.5 - 2004 DODGE TRUCKS

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