2005-2009 Dodge Cummins Air Dog Install Manual

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NEW ZEALAND PATENT532356

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INSTALLATION MANUAL

DF-100 & 150 w/Preset RegulatorDF-165 w/Adjustable Regulator

CUMMINS POWERED

DODGE TRUCKSModel Year 2005 THROUGH 2009

High Performance Fuel System

PLEASE READ THESEINSTRUCTIONS THOROUGHLY

BEFORE BEGINNING INSTALLATION!

1412 CREEK TRAIL DRIVE 573 635-0555 VOICE JEFFERSON CITY, MO 65109 573 635-0778 FAX

www.pureflowtechnologies.com

2

PRESET OR ADJUSTABLE

PRESSURE REGULATOR

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

DEMAND FLOW SERIESFLOWS 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!

SMALL RETURN LINE FOR AIR, VAPOR AND

FOAM

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Large -8 JICBulkhead Fitting For Fuel Supply!

Line!

PureFlow® TechnologiesHigh Flow Fuel Module Upgrade!

Converts your stock Fuel Module to a High Flow System!

NO MORE Quarter Tank fuel Problems!

NO More Drilling Holes in Your Fuel Tank to Install anAftermarket Draw Straw!

Large ½” ID OE Style Flex

Tube!

Injector LineClamp!

Stainless Steel Suction Tube!

AirDog®II Return Line Connects to

Original Fuel Module Suction

Tube!

AirDog®II Returns Directly Into the Collection Basket

Suction Tube Mounting Block w/Set Screw!

By passes In-TankFuel Pump!

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OVERVIEW

Welcome to PureFlow® Technology’s AirDog®IIFuel Air Separation, Filtration and Delivery System for the Diesel Engine

The AirDog®II Fuel Preporator® original Fuel Air Separation System, is a premium replacement fuel pump 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 flowto 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. The regulator components are made of stainless steel. All AirDog®II systems include a Fuel Module Up-Grade Kit and a complete installation kit.

The AirDog®II DF-100 is recommended for stock and slightly modified 5.9Land 6.7L Cummins Diesels.

The AirDog®II DF-150 and DF-165 Adj. are recommended for highly modified 5.9L and 6.7L Cummins Diesels.

PureFlow® products are manufactured with a personal touch, unsurpassed attention to detail

andthe most stringent Quality Assurance!

TYPICAL INSTALLATION LAYOUT

Figure 1The 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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PureFlow® Technologies, IncAirDog®II Demand Flow Dodge 2005 - 2009Section 1 Table of Contents

TABLE OF CONTENTSSection 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…………………………..……………………………….5.9L CP3

Section 5 B…………………………………………………………...6.7L 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

Lifetime Limited Express Warranty

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PureFlow® Technologies, IncAirDog®II Demand Flow Dodge 2005 - 2009Section 2 Installation & Safety Guidelines

AirDog®IIMODEL 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. Disconnectthe 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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PureFlow® Technologies, IncAirDog®II Demand Flow Dodge 2005 - 2009Section 3 Parts List

AirDog® Parts ListQTY DESCRIPTION Part Number IMAGE

1 Installation Manual ADI-D-9802P-100/150

1 AirDog®IIDF-100 PresetDF-150 PresetDF-165 Adj.

1 AirDog®II Mounting Bracket 001-3C-0004

1 Mounting Bracket Hardware Kit, Includes: 4 Socket Head Cap Screws, 1/4-20 x 1-1/4" Lg. 4 Lock Washers, 1/4” 4 Hex Nuts, 1/4-20

901-61-0101-PM

1 Frame Bracket010-3C-0002PC010-3C-0001PC

1 Frame Bracket Hardware Kit, Includes: 3ea 3/8” x 4-1/2” Hex Head Bolt, 3ea 3/8” Nut 3ea 3/8” Lock Washer

(Included In)

901-61-0101-PM

1 Spacer 010-3C-0003A1 Spacer Bracket Hardware Kit, Includes:

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

(Included In)

901-61-0101-PM

1 Wiring Harness 5E-2-014

12 Ft. ½” Fuel Line 4C-1-02-08-0029 Ft 1/4” Fuel Return Line 4C-02-04-001

1 Bundle of Plastic Ties 5H-2-1-06/12

2 -8 JIC x 3/8” NPT 4A-1-02-08-06-S1 -4 JIC x 1/8” NPT 4A-1-01-04-02-S

1 3/8” Quick Connect x ¼” Hose Barb (PureFlow® Brand)4A-1-17-A-01-AN

1 -4 JIC Swivel x ¼” Hose Barb4A-1-01-04-04-B

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 12mm x -8 JIC w/O-ring 001-4A-1-0002-S1 Fuel Module Up Grade Kit 901-01-0500

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PureFlow® Technologies, IncAirDog®II Demand Flow Dodge 2005 - 2009Section 4 AirDog®II & Mounting Brackets

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

Figure 2 Figure 3

4-1. Assemble the AirDog®II mounting bracket to the frame bracket.

Figure 4 Figure 54-2. 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.

Figure 8

Figure 9

4-6. Attach the AirDog®II to the frame bracket assembly.

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PureFlow® Technologies, IncAirDog®II Demand Flow Dodge 2005 - 2009Section 4 AirDog®II & Mounting Brackets

Installing the AirDog® & Mounting Brackets on the Truck’sFrame, 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

OutsideThe

Frame

Figure 10 Or Figure 11

InsideThe

Frame

Figure 12 Figure 13

For this installation, the AirDog®II is mounted inside the frame!

4-7. 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 144-8. 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 used to support the frame during the manufacturing process If this bracket is on your frame rail and obstructs the proper positioning of the AirDog®II mounting bracket, you may remove part or all of it, as needed. Be very careful not to damage the frame flange!

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PureFlow® Technologies, IncAirDog®II Demand Flow Dodge 2005 - 2009Section 5 A Fuel Lines

Section 5A: Fuel Supply Line from the AirDog® to the CP-3For the 5.9L Cummins Engine

The AirDog®II fuel filter is made by Fleetguard and has a 2 micron Stratapore™ media. When installing the AirDog® 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 CP-3 high pressure pump.

Figure 17 Figure 18

5A-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 COULD BREAK!

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

CP-3 Fuel Supply Line AirDog®II Fuel Line to Engine

Figure 19

Figure 20

5A-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 21 Figure 22 Figure 23

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PureFlow® Technologies, IncAirDog®II Demand Flow Dodge 2005 - 2009Section 5 A Fuel Lines

Fuel Supply Line from the AirDog® to the CP-3For the 5.9L Cummins Engine, cont’d!

5A-5. Connect one end of the fuel line to thefitting on the AirDog®II port marked“ENGINE”. Properly torque the fitting.

To “ENGINE”

Figure 245A-6. Route and connect the other end of

the fuel line with the 90o fitting to thefuel inlet fitting just installed on the CP-3. When tightening the swivel,use a back up wrench on the 12mm fitting to preventing breaking it.

Figure 25NOTE: 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 recommended to cap the inlet port to the OE fuel pump and outlet port of the bypassed filter canister.

Figure 26

Section 5 BFuel Supply Line from the AirDog®II to the CP-3

For the 6.7L Cummins Engine

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.

5B-1. Remove the Quick Connect fitting and the original factory fuel supply line at the fuel inlet port of the CP-3 high pressure pump.

Figure 27

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PureFlow® Technologies, IncAirDog®II Demand Flow Dodge 2005 - 2009Section 5 B Fuel Lines

Fuel Supply Line from the AirDog®II to the CP-3For the 6.7L Engine, cont’d

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 Quick Connect fitting. Properly torque the 12mm x -8 flare fitting.

Figure 28Caution: Do not over torque the 12mm fitting, IT COULD BREAK!

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 29

Figure 30

5B-4. Install a straight -8 Swivel x 1/2" Push Lock on each end of the fuel line connecting the engine to the AirDog®II.

Figure 31 Figure 32 Figure 33

5B-5. Connect one end of the fuel line to thefitting on the AirDog®II port marked“ENGINE”. Properly torque the fitting.

To “ENGINE”

Figure 34

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PureFlow® Technologies, IncAirDog®II Demand Flow Dodge 2005 - 2009Section 5 B Fuel Lines

Fuel Supply Line from the AirDog® to the CP-3For the 6.7L Cummins Engine, cont’d!

5B-6. Route and connect the other end of thefuel line to the fuel inlet fitting justinstalled on the CP-3. When tightening theswivel, use a back up wrench on the 12mmfitting to preventing breaking it.

Figure 35

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 recommended to cap the outlet port of the bypassed filter canister.

Figure 36

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Fuel Module (Collection Basket)

Suction Tube(Draw Straw)

PureFlow® Technologies, IncAirDog®II Demand Flow Dodge 2005 - 2009Section 5 C High Flow Fuel Module

Overview

The AirDog®II Fuel Module High Flow Upgrade!

The stock 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 develop which can cause afuel 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

Figure 37

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

Waves

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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 Steel Clamps

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

1 ea. Stainless Steel Suction Tube ½” ID

1Tube Locktite® Sealer

1 ea. Mounting Block & Stainless Steel Set Screw

3 ea. Tie Straps

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INSTALLING THE AIRDOG®II FUEL MODULE UPGRADE!

The AirDog®II DF-100, DF-150 & DF-165 include a Fuel Module Upgrade Kit. 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 38

Figure 39

Figure 40

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

Figure 41 Figure 42

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INSTALLING THE AIRDOG®II FUEL MODULE UPGRADE!Cont’d!

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 43

Figure 44

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

Figure 45

Figure 46

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

Figure 47

Figure 48

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

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INSTALLING THE AIRDOG®II FUEL MODULE UPGRADE!Cont’d!

5C-5. Install the sealing washer and lock nut on the bulkhead fitting and tighten.

Figure 49 Figure 50

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

Figure 51

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 52

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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INSTALLING THE AIRDOG®II FUEL MODULE UPGRADE,Cont’d!

5C-10. Place the ‘Suction Tube Block’ back on the fuel module basket and insert the suction tube into the block.

Figure 53

Figure 54

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 55 FIGURE 56

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

FIGURE 57 FIGURE 585C-13. Cut the original suction tube off just above the connector and secure with the two tie

straps as shown. The original suction tube can now be used for the AirDog®II air/vapor return line.

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INSTALLING THE AIRDOG®II FUEL MODULE UPGRADE!CONTINUED

VERY IMPORTANT: Before re-installing the collection basket, it is necessary to disable the in tank fuel pump.

5C-14. You may either disconnect the power lead to the pump while the collection basket is out of the tank and accessible……

FIGURE 59

5C-15. Re-install the modified fuel module in the fuel tank. Be careful to not bend the sending unit float arm when reinstalling the fuel module.

5C-16. 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®II 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.

Figure 60

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

Figure 615D-3. Install a ¼” hose barb x -4 JIC swivel on the other end of the fuel line.

Return Line to Tank

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PureFlow® Technologies, IncAirDog®II Demand Flow Dodge 2005 - 2009Section 5 D Fuel Lines

Air/Vapor Return Line from the AirDog®II to the Fuel Module!

5D-4 Connect the end of the Air/Vapor return line with the -4swivel to the -4 JIC fitting on the AirDog®II port marked “TANK”.

Figure 62

Figure 63

AirDog®II 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!

Fuel Suction Line for AirDog®II5E-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 64 Figure 65

5E-2. Install a straight -8 swivel x 1/2" Push Lock into each end of the fuel line. Lubricate the barb end of Push the fuel line completely the Push Lock fitting with oil. onto the barb end of the fitting.

Figure 66 Figure 67

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PureFlow® Technologies, IncAirDog®II Demand Flow Dodge 2005 - 2009Section 5 E Fuel Lines

Fuel Suction Line for AirDog®II

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

Figure 68

Figure 69

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

Figure 70PureFlow® 3/8th quick connect fitting features TWO O-rings for better sealing!

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Power Supply Red +

Power Supply Black -

Relay Trigger Lead

ECM Pump Lead Connectors,Female

PureFlow® Technologies, IncAirDog®II Demand Flow Dodge 2005 - 2009Section 6 Electrical Harness

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 71The AirDog®II is activated by the ECM through a relay controlled wiring harness connecting directly to the original ECM Deutsch pump connector.

Figure 72CAUTION: 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 Vehicle6-1. Secure the relay and fuse holder to the vehicle.

Figure 73 Figure 74

Pressure Sensor Lead

Motor Power Supply Lead

Low Fuel PressureIndicator Light Leads

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Connecting the AirDog®II Relay Control to the ECM

6-2. To connect the AirDog®II relay trigger lead to the ECM fuel pump lead, locate the Orange w/Red Stripe wire coming off of the Fuel Module (Fig. 75). The Orange w/Red Stripe wire will be the right hand wire coming out of the Fuel Module.

Figure 75

Figure 76

Orange w/Red Stripe ECM Fuel Pump Lead!

6-2. Cut the wire back far enough from the fuel module (Fig. 76) to make it easy to work with.

6-3. Crimp the female covered connector to the Original “In-Tank” Fuel Pump ECM Lead (Fig.76).Seal the connection with the “heat Shrink” supplied. Figure 77

6-4. Route and connect the AirDog®II relay lead (Male Connector) to the ECMpump lead. Figure 78

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 (-) Red (+)

6-5A. Route the Red & Black power supplyleads to the alternator. Connect theBlack (-) lead to the alternatorChassis Ground connection. Connectthe Red (+) lead to the alternator HotLead going to the battery.

Figure 79

OR6-5B. 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 80

25


Connecting the Wiring Harness to the AirDog®II

6-5. Route the wiring harness to the AirDog®IIand connect the 2 pin Deutsch connectorto the corresponding connector on the AirDog®II.

Figure 81

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 82 Figure 83Select a suitable location to install the Indicator Light!

6-7. 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.

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PureFlow® Technologies, IncAirDog®II Demand Flow Dodge 2005 - 2009Section 7 Initial Startup Procedures

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 withdiesel 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 and will be very noisy. Additionally, should the suction line be pinched or restricted, cavitation can cause vapor to form which will also cause pump noise.

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.

27

PureFlow® Technologies, IncAirDog®II Demand Flow Dodge 2005 - 2009Section 8 Fuel Filter & Pre-filter

Filter Service RecommendationsPlugging 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 AirDog®II 2 Micron Stratapore™ Wire Screen

Fuel Filter Pre-filter

Drain Valve Limited Edition Model Shown

Figure 84

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!

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PureFlow® Technologies, IncAirDog®II Demand Flow Dodge 2005 - 2009Section 9 Cleaning the Gerotor Assembly

Cleaning Foreign Debris from the Gerotor Assembly Step 1 Step 2 Step 3Remove the four (4) buttons Carefully remove the O-ring, Remove and clean the Gerotor.head cap crews that secure you will need to re-use it. Be very careful not to damage the Gerotor cap. the Gerotor.

Step 4 Step 5 Step 6Clean the inside of the Replace the O-ring and Align the teeth and Gerotor pocket. center gear. install the outer gear.

Step 7 Step 8 Install the Gerotor cap. Be very Replace the cap into careful to index the cap to position position. Be very careful, the wide space between the half do not pinch the O-ring. moon cuts to the bottom. 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).

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PureFlow® Technologies, IncAirDog®II Demand Flow Dodge 2005 - 2009Section 10 Pressure Regulator

AirDog®II DF-165 with Adjustable Pressure Regulator!

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

ALL NEWOriginal AirDog® “Ball and Spring” Adjustable Regulator w/ all Stainless

Regulator 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 assemblyand remove the spring.

Step 3. Slide the new spring into position,replace the piston.

Step 4. Replace the assembly inthe base. Tightenthe Base Nutto proper torque.

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

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.

PRESSUREADJUSTMENT

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NOTES

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Copyright © 2009 PFT Bulletin No. ADII-DF0509PureFlow Technologies, Inc. Printed 09All Right Reserved Revised March 3, 2009

Documents

2005-2009 Dodge Cummins Air Dog Install Manual