Airdog II DF-100 User manual

PureFlow AirDog®
AirDog®II DF-100 & DF-165 2005-Current Cummins Diesel
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#16

PureFlow AirDog®
AirDog® II DF-100 & DF-165 2005-Current Cummins Diesel
2
SMALL and COMPACT
7” Long X 3.2” Wide X 10” Tall

PureFlow AirDog®
AirDog®II DF-100 & DF-165 2005-Current Cummins Diesel
3
OVERVIEW
Thank you for your purchase and welcome to PureFlow AirDog®II-4G fuel air
separation and delivery system for the 2005 and up Cummins 24V diesel engine.
The AirDog®II-4G Fuel Preporator® is an all in one premium high pressure fuel pump
and filtration system for the 6.7L Cummins diesel. The system removes water, particulates,
and entrained air from the diesel 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 and flow rate to meet the demands of the engine under all operating
conditions.
The AirDog®II-4G systems feature a built in adjustible pressure regulator. All
AirDog®II and AirDog®II-4G systems include a complete installation kit.
The AirDog®II-4G for this particular application are preset at 15-17psi from factory
for a stock application. The regulator is adjustible up to 75psi for fine tuning the system for
performance upgrades. WARNING: RUNNING THE PUMP ABOVE 75PSI WILL DECREASE THE
LIFE OF THE PUMP SIGNIFICANTLY AND MAY VOID THE WARRANTY.
PureFlow AirDog products are manufactured in Shelbyville Indiana by a team of
skilled workers with unsurpassed attention to detail and using the most stringent quality
assurance.
TYPICAL INSTALLATION LAYOUT
The AirDog®II-4G draws fuel from the fuel tank at a constant flow, removing water,
particulates, and air/vapor. A regulated pressurized flow is maintained to meet the engine’s
varying fuel demands. The The AirDog®II-4G regurns the separated air/vapor to the fuel
tank through the fuel tank.

PureFlow AirDog®
AirDog®II DF-100 & DF-165 2005-Current Cummins Diesel
4
QUICK CONNECT COMPONENT OVERVIEW
Provided in this kit is an OE style quick connection system. This system works
to allow for a quick, clean, and professional install.
SAE J2044 Quick Connect System
The SAE J2044 quick connect system is the most commonly used system in the
automotive industry. The images below show the formation of SAE J2044
connection. To connect the assemblies, simply insert the male end form into
the mating female connector. Push firmly until you hear it “click” into place.
To disconnect the fittings, press down and hold the tabs on the female
connector while you firmly pull the assembly apart.

PureFlow AirDog®
AirDog®II DF-100 & DF-165 2005-Current Cummins Diesel
Section 1 Table of Contents
5
TABLE OF CONTENTS
Section 1……………………………….…………………..Table of Contents
Section 2…………………………………Installation and Safety Guidelines
Section 3…………………………….…..…..……………………….Parts List
INSTALLATION PROCEDURES
Section 4…………………….……………Fittings, Brackets, and Mounting
FUEL LINES
Section 5……………………………………………..….Fuel Line Assembly
Section 6A………………………..……………………Supply Line 5.9L CP3
Section 6B……………………………………………Supply Line 6.7L CP3
Section 6C………………………………………………....Fuel Suction Line
Section 6D……………………...……….………………Fuel Return to Tank
ELECTRICAL HARNESS
Section 7…..………………………………………..….……..Wiring Harness
Section 8..………….……………………………….Initial Startup Procedure
MAINTENANCE AND UPGRADES
Section 9……………….………….…...…Filter Service Recommendations
Section 10…………………….…………...Cleaning the Gerotor Assembly
Section 11………………….……..………Pressure Regulator Adjustment
Section 12…………………………………………Changing the Fuel Filters
Section 13…………………………………………..…..Warranty Procedure

PureFlow AirDog®
AirDog®II DF-100 & DF-165 2005-Current Cummins Diesel
Section 2 Installation and Safety Guidelines
6
AirDog®II
INSTALLATION GUIDELINES!
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®AIRDOG
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. When installing the fuel module up-grade, be sure to drill the two additional ½” fuel
ports as shown!
5. When installing the AirDog®II fuel lines, be sure to connect the ORIGINAL ENGINE
RETURN LINE to the fuel tank as it was from the factory when the installation is
complete!
If any installation procedure is uncertain, contact
PUREFLOW AIRDOG for technical assistance.
SAFETY GUIDELINES!
CAUTION! Please be sure to chock the vehicle’s tires to prevent rolling.
CAUTION! Please use proper supports when working beneath an elevated vehicle.
CAUTION! Most diesel pickups have two (2) 12volt batteries. Disconnect the
battery cables to both batteries before proceeding with the AirDog®II
installation.
CAUTION! Vehicle frame rails should not be drilled into or welded on.
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.
NOTE: The pictures used in this manual are for example only and may not be exactly the
same as your truck.

PureFlow AirDog®
AirDog®II DF-100 & DF-165 2005-Current Cummins Diesel
Section 3 Parts List
7
AirDog®Parts List
QTY
DESCRIPTION
PART NUMBER
IMAGE
1
AirDog®II
DF-100
or
DF-165
1
AirDog®II Mounting Bracket
001-3C-0004
1
Mounting Hardware Kit,
901-61-0102-PM
1
Frame Bracket
010-3C-0002
010-3C-0001
1
Wiring Harness
5E-2-014
1
Bundle of Plastic Ties
5H-2-1-06/12
1
Fuel Module Up Grade Kit
901-01-0510
1
Spacer
010-3C-0003-A-P
1
20ft of Fuel Line
HS20
3
1/2” Straight Hose Quick Connect Fitting
FQC12S
1
1/2" 90° Hose Quick Connect Fitting
FQC1290
1
3/8” 90° Hose Quick Connect Fitting
FQC3890
1
3/8” Straight Hose Quick Connect Fitting
FQC38S
1
12mm X ½” male SAE J2044 Fitting
WAP102
1
Seal Washer (installs on WAP102 fitting)
1P-5-DS
1
Customer Service O-ring Replacement Kit
901-05-0100
2
1/2” Male J2004 Quick Connect x 9/16” UNF
08J2044916UNF
1
3/8” Male J2004 Quick Connect x 5/16” UNF
06J2044516UNF

PureFlow AirDog®
AirDog®II DF-100 & DF-165 2005-Current Cummins Diesel
8
ILLUSTRATION OF QUICK CONNECT COMPONENTS

PureFlow AirDog®
AirDog®II DF-100 & DF-165 2005-Current Cummins Diesel
Section 4 Fittings, Brackets, and Mounting
9
Installing the j2044 Quick Connect Fittings into the
AirDog®II OR AirDog®II-4G Filter Base
4-1. Dip the threaded end of the 1/2” male J2044 quick connect X 9/16” UNF
(08J2044916UNF) fittings into clean motor oil and hand-thread into the “ENGINE”
and “FUEL IN” ports of the AirDog®II-4G filter base as illustrated in figures 1, 2, and
3. Using a 3/4” deep socket, torque the fittings to 120in-lb or 10ft-lb. DO NOT
overtighten the fittings or damage may occur!
4-2. Dip the threaded end of the 3/8” male J2044 quick connect X 5/16” UNF
(06J2044516UNF) fitting into clean motor oil and hand-thread into the return port of
the the AirDog®II-4G filter base as illustrated in figures 1 and 4. Using a 5/8” deep
socket, torque the fitting to 60in-lb or 5ft-lb. DO NOT overtighten the fittings or
damage may occur!
Figure 1
Figure 2
Figure 3
RETURN
ENGINE
FUEL IN
Figure 4
RETURN
ENGINE

PureFlow AirDog®
AirDog®II DF-100 & DF-165 2005-Current Cummins Diesel
Section 4 (Continued) Fittings, Brackets, and Mounting
10
4-3. 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 5 using the four bolts,
lock washers, and nuts included in the mounting bracket hardware kit (figure 6).
Properly torque all fasteners! You will need a 3/16” allen and a 1/2" wrench. The
bracket assembly should look like figure 7.
4-4. Attach the AirDog®II-4G to the frame bracket assembly as shown in figure 8 using
the supplied hardware in the mounting bracket hardware kit.
NOTE: We recommend installing the AirDog® on the inside of the frame rail, but we
understand some applications just don’t have the room. The photos in this manual may not
be the same as your application.
4-5. Be sure to tuck the AirDog®II-4G as far up as possible without it rubbing on anything
to prevent damage from road debris. The braket assembly is adjustible to achieve
this.
Figure 5
Figure 6
Figure 7
Figure 8

PureFlow AirDog®
AirDog®II DF-100 & DF-165 2005-Current Cummins Diesel
Section 4 (Continued) Fittings, Brackets, and Mounting
11
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!
4-6. Clamp the frame between the AirDog® bracket assembly and the backing plate
(figure 11) using the 3/8” bolts, lock washers, and nuts included in the kit. You will
need two 9/16” wrenches. Properly torque all fastners! BE SURE to mount the
AirDog®II with the “FUEL IN” port toward the rear of the vehicle (Figure 12).
Figure 9
Figure 10
Figure 11
Figure 12
VEHICLE
FRONT
VEHICLE
REAR
FUEL IN

PureFlow AirDog®
AirDog®II DF-100 & DF-165 2005-Current Cummins Diesel
Section 5 Fuel Line Assembly
12
Assembling the Fuel Lines
This kit includes a length of fuel line and separate fuel line ends to allow for
much cleaner looking installations! Assemble the fuel lines as you install
them. You won’t want to pre-assemble the hoses or your lengths may be off.
5-1. Take the fuel line end and lubricate the barbed end with clean motor oil (Figure 13)
and press it into the fuel line (HS20) until all three barbs are covered (Figures 14 and
16). The fuel line end should look like Figure 15.
5-2. Now plug that fuel line with that fitting into the connection on the either the AirDog
or the truck where the manual calls it out.
5-3. Run the fuel line along the frame away from any hot or moving parts such as exhaust
or the driveshaft (Figure 16). Cut the hose to length and insert the other fuel line
end that the manual calls out into the fuel line as outlined in step 5-1.
NOTE: Hose clamps are not needed for these push-lock connectors.
Figure 13
Figure 15
Figure 14
Figure 16

PureFlow AirDog®
AirDog®II DF-100 & DF-165 2005-Current Cummins Diesel
Section 6A Fuel Lines (Supply Line 5.9L)
13
Installing the Fuel Supply Line from the AirDog®to the CP3
Injection Pump 5.9L
When installing the AirDog®fuel system, it is recommended to bypass the factory filter
canister for optimum engine performance.
6A-1. Using a 17mm wrench, remove the “banjo bolt” (Highlighted in Figure 17) and the
original factory fuel supply line at the fuel inlet port of the CP-3 high pressure pump.
6A-2. Install the 12mm x 1/2” male SAE J2044 (WAP 102) fitting with the seal washer (1P-
5-DS) supplied into the inlet port of the CP3 injection pump (Figure 18) once the
original fitting is removed. Do not over tighten the fitting. It may crack or break.
Either remove or bend the original supply line out of the way.
WAP102
1P-5-DS
Figure 17
Figure 18

PureFlow AirDog®
AirDog®II DF-100 & DF-165 2005-Current Cummins Diesel
Section 6A (Continued) Fuel Lines (Supply Line 5.9L)
14
6A-3 Assemble one end of the hose (Reference section 5) 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.
6A-4. Run the fuel line along the frame as mentioned in step 5-3 to the “Engine” port in
the AirDog®. Cut the fuel line to length and insert fuel line end FQC12S per step 5-1.
Once the connector is installed, connect it to the male J2044 fitting in the “Engine”
port in the AirDog®. A “click” will be heard once properly connected.
6A-5. It is advised to remove the factory supply lines between the tank and the filter
canister. Also remove the factory supply line between the filter canister and the
injection pump. Then plug the ports on the filter canister. This will prevent fuel
spillage.
NOTE: Be sure to keep the ORIGINAL ENGINE RETURN LINE connected as it is from the
factory! In many cases the return runs thru the flange of the filter canister.
Figure 19
FQC1290
HS20
FQC12S
HS20
Figure 20
Figure 21

PureFlow AirDog®
AirDog®II DF-100 & DF-165 2005-Current Cummins Diesel
Section 6B Fuel Lines (Supply Line 6.7L)
15
Installing the Fuel Supply Line from the AirDog®to the CP3
Injection Pump 6.7L
When installing the AirDog®fuel system, it is recommended to bypass the factory filter
canister for optimum engine performance.
6B-1. Using a 17mm wrench, remove the “banjo bolt” (Highlighted “2” in Figure 22) and
the original factory fuel supply line at the fuel inlet port of the CP3 high pressure
pump.
6B-2. Install the 12mm x 1/2” male SAE J2044 (WAP 102) fitting with the seal washer (1P-
5-DS) supplied into the inlet port of the CP3 injection pump (Figure 23) once the
original fitting is removed. Do not over tighten the fitting. It may crack or break.
Either remove or bend the original supply line out of the way.
6B-3. Refer to steps 6A-3 and 6A-4 to install the fuel supply line for the 6.7L CP3.
WAP102
1P-5-DS
Figure 22
Figure 23

PureFlow AirDog®
AirDog®II DF-100 & DF-165 2005-Current Cummins Diesel
Section 6C Fuel Lines (Suction Line from Tank)
16
Fuel Suction Line for AirDog®II
6C-1. Assemble one end of the suction fuel line (reference section 5) using fuel line end
FQC12S. Once the end is pressed in, connect it to the J2044 fitting in the “Fuel In”
port on the AirDog® A “click” will be heard when the fitting is properly connected.
FUEL MODUEL UPGRADE PRE-INSTALLATION STEPS
6C-2. Either remove the bed or drop the tank for access to the collection basket.
This AirDog®kit includes a Fuel Module Upgrade (P/N 901-01-0510) to accommodate
the high flows of this system. To install the Fuel Module Upgrade, it is necessary to either
drop the fuel tank or to lift the truck bed.
NOTE: 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.
When Dropping the Tank, Always Remember, Safety First!
Figure 27
Figure 26
Figure 25
FQC12S
HS20
Figure 24

PureFlow AirDog®
AirDog®II DF-100 & DF-165 2005-Current Cummins Diesel
Section 6C (Continued) Fuel Lines (Suction Line from Tank)
17
If you choose to remove the bed, properly support the truck bed to prevent
serious injury or death!
NOTE: The fuel tank and truck bed used for the pictures are examples only and may not be
exactly the same as your tank.
6C-3. Once either the tank has been dropped or the bed removed, remove the collection
basket as shown in figures 30 and 31.
Figure 29
Figure 28
Figure 31
Figure 30

PureFlow AirDog®
AirDog®II DF-100 & DF-165 2005-Current Cummins Diesel
Section 6C (Continued) Fuel Lines (Suction Line from Tank)
18
6C-4. Refer to the installation instructions within the fuel module upgrade kit (P/N 901-
01-0510) and install the fuel module upgrade kit.
6C-5. Run the fuel line along the frame as mentioned in step 5-3 to the bulk head male
quick connect installed during the fuel module upgrade. (see Fig 32). Cut the fuel
line to length and insert fuel line end FQC12S per step 5-1. Once the fuel line end is
pressed in, connect it to the male J2044 fitting on the Module Upgrade. A “click”
will be heard when the fitting is properly connected.
NOTE: Figure 32 is for visual reference only. The fuel module in your vehicle may appear
different.
6C-6. If the fuel tank was dropped to install the fuel module upgrade, re-install the fuel
tank. If the truck bed was removed, reinstall the bed.
Figure 32
FQC12S
HS20

PureFlow AirDog®
AirDog®II DF-100 & DF-165 2005-Current Cummins Diesel
Section 6D Fuel Lines (Return Line to Tank)
19
Return Line to the Fuel Tank
6D-1. Assemble one end of the hose (Reference section 5) using Fuel line end FQC3890
and plug it into the “Return” J2044 fitting installed in the AirDog® (Figure 33). A
“click” will be heard once the fitting is properly connected.
6D-2. Run the fuel line along the frame as mentioned in step 5-3 to the factory J2044 male
3/8” return quick connect fitting. Cut the fuel line to length and insert fuel line end FQC38S
per step 5-1. Once the connector is installed, connect it to the male J2044 fitting in the
factory oultlet/suction line in the fuel module. The factory return from the engine must be
reconnected to its factory location. A “click” will be heard once properly connected.
FQC38S
HS20
Figure 34
Figure 33
FQC3890
HS20

PureFlow AirDog®
AirDog®II DF-100 & DF-165 2005-Current Cummins Diesel
Section 7 Wiring Harness
20
AirDog®Wiring Harness Install
WIRING DIAGRAM
*CAUTION: If the OPTIONAL Low Pressure Indicator Light is not used, be sure to insulate
the two (2) #10 Indicator Light connectors and pressure sensor lead to prevent accidental
contact.
*The light kit is sold separately and is not included in this kit.
Secure the Relay and Fuse Holder to the Vehicle
7-1. Secure the relay and fuse holder to the vehicle. Be sure to rout the wires away from
any moving parts. The relay is illustrated below in figure 36. The fuse holder
mounting is the same concept.
FEMALE POWER
LEAD JUMPER
PLUGS INTO FUEL
MODULE
INDICATOR
LIGHT LEADS*
AirDog®
MOTOR LEAD
PRESSURE
SWITCH
LEAD*
BATTERY
NEGATIVE LEAD
BATTERY
POSITIVE LEAD
FUSE HOLDER
WITH 20A FUSE
RELAY
Figure 35
Figure 36
MALE POWER LEAD
JUMPER
PLUGS INTO
FACTORY HARNESS