PureFlow AirDog DF-100-5G User manual

DF-100-5G
WITH IN-TANK RETROFIT PUMP
DF-165-5G
DF-220-5G
1998.5-2004 CUMMINS
INSTALLATION INSTRUCTIONS
PLEASE READ AND CHECK CONTENTS
BEFORE INSTALLATION
PUREFLOW AIRDOG
705 W MAUSOLEUM RD.
SHELBYVILLE, IN 46176
877-421-3187
PUREFLOWAIRDOG.COM
#14
PATENT PROTECTED:
https://pureflowairdog.com/p-35853-patents.html

1
TABLE OF CONTENTS
TITLE PAGE
INTRODUCTION 2
SAFETY GUIDELINES 3
PRE-INSTALLATION CHECKS 4
PARTS LIST 5
QUICK CONNECT FITTING OVERVIEW 7
QUICK CONNECT FITTING ILLUSTRATION 8
PUMP FITTING INSTALLATION DF-100 & DF-165 9
PUMP CRADLE BRACKET INSTALLATION 11
PUMP TO FRAME INSTALLATION 12
FUEL LINE ASSEMBLY OVERVIEW 15
ENGINE LINE INSTALLATION 1998.5-2002 VP-44 16
RETURN LINE INSTALLATION 19
WIRING INSTALLATION 29
INITIAL STARTING PROCEDURE 32
FILTER SERVICE 33
GEROTOR PUMP SERVICE 34
WARRANTY
35
ADJUSTING FUEL PRESSURE
36
PUMP FITTING INSTALLATION DF-220 10
INLET LINE DF-100 & DF-165 ONLY 20
INLET LINE DF-220 ONLY 27
ENGINE LINE INSTALLATION 2003-2004 CP3 18

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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. If properly set up per these
instructions, the pump head carries a lifetime warranty to the original purchaser.
THIS WARRANTY IS NON-TRANSFERRABLE!
The AirDog® II-5G uses an adjustable diaphragm fuel pressure regulator to
regulate the fuel pressure to the injection system. The pressure for this application is
preset from the factory at 15-17psi. If a different pressure is desired, go to page 35 for
instructions on how to adjust the pressure. WARNING: RUNNING THE PUMP ABOVE
75PSI FOR THE DF-100 AND DF-165 AND ABOVE 55PSI FOR THE DF-220 WILL
DECREASE THE LIFE OF THE PUMP SIGNIFICANTLY AND MAY VOID THE
WARRANTY. MORE FUEL PRESSURE DOES NOT MEAN MORE FUEL FLOW AND
TOO HIGH OF PREESURE MAY DAMAGE YOUR INJECTION SYSTEM! MORE
FUEL PRESSURE DOES NOT MEAN MORE FUEL FLOW!
OVERVIEW ON HOW THE SYSTEM OPERATES
The AirDog® draws fuel from the tank from a high flow suction tube installed in
the tank. The fuel is then pulled through a water separator before being pressurized
through the Gerotor pump. The pressurized fuel is sent through the 2 micron fuel filter
before being sent to the engine. The pump maintains pressure through a diaphragm
fuel pressure regulator that recirculates fuel back through the water separator. The
separated air from the diesel fuel is returned through a filler neck return tee.

3
SAFETY GUIDELINES
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.
DANGER indicates a hazardous situation which, if not avoided,
WILL result in death or serious injury.
WARNING indicates a hazardous situation which if not avoided,
COULD result in death or serious injury.
CAUTION indicates a hazardous situation which if not avoided,
COULD result in minor or moderate injury
NOTICE indicates a preferred installation procedure.
SAFETY INSTRUCTIONS

4
PRE-INSTALLATION CHECKS
The installation of your AirDog® 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 missing or damaged parts! 317-421-3180
2. Read the installation manual completely. Understand how the system operates and understand
the installation recommendations before beginning the installation.
3. The installation recommendations contained herein are suggested installation guidelines only.
Individual installations may vary.
4. If any installation procedure is uncertain, contact PUREFLOW® AIRDOG for technical
assistance.
5. When installing the AirDog® fuel lines be sure to keep the ORIGINAL ENGINE RETURN LINE
connected as it is from the factory!
SAFETY GUIDELINES!
Please be sure to chock the vehicle’s tires to prevent rolling
Please use proper supports when working beneath an elevated vehicle
Most diesel pickups have two (2) 12 volt batteries. Disconnect the battery
cables to both batteries befire proceeding with the AirDog® installation
Vehicle main framerails should not be drilled into or welded upon.
Wear safety glasses or shield when using tools such as drills
and grinders or when using a punch or chisel
Prolonged exposure to loud noise can cause impairment or loss of
hearing. Wear suitable hearing protective devices such as ear muffs
or ear plugs to protech against loud noises.
Use common sense when routing fuel lines and electrical wiring. Keep them
away from hot exhaust components and/or moving parts. Properly secure
lines to prevent chaffing.

5
PARTS LIST
QTY DESCRIPTION PART NUMBER IMAGE
1 AirDog® II-5G DF-100, DF-165, OR
DF-220
1 AirDog® Cradle Bracket 001-3C-0004
1 Frame Bracket Set 010-3C-0001
010-3C-0002
1 Mounting Bracket Hardware 901-61-0102-PM
1 Spacer Block 010-3C-0003-A-P
1 Wiring Harness 5E-2-011-HD
1 1.5” Filler Neck Tee with Clamps 001-4A-1-0150
1 3/8” 90deg Hose Quick Connect Fitting FQC3890
112mm X ½” male SAE J2044 Fitting WAP102
13/8” Male SAE J2044 Quick Connect x 7/16 ORB 06J2044716UNF
1High Flow Suction Tube WAP109
1 Zip Tie Bundle 5H-2-1-B
1 Customer Service Replacement O-ring Kit 901-05-0500
1
1
HVC-467-16
4C-2-1-10
Vacuum Cap
Vacuum Cap Hose Clamp
1P-5-DSSealing Washer (installs on WAP102 fitting)
11/2” 90deg Hose Quick Connect Fitting FQC1290
1
COMMON PARTS

6
23/4-16 ORB Male to -10 JIC Male Fitting 4A-1-02-10-08-S
2-10 JIC Female to 5/8” Barb 4A-1-09-10-10-B
PARTS LIST CONTINUED
QTY DESCRIPTION PART NUMBER IMAGE
DF-100-5G AND DF-165-5G ONLY
120ft of 1/2” Fuel Line HS20
41/2” Straight Hose Quick Connect Fitting FQC12S
31/2” Male SAE J2044 Quick Connect x 3/4 ORB 08J2044-3/4UNF
QTY DESCRIPTION PART NUMBER IMAGE
DF-220-5G ONLY
114ft of 1/2” Fuel Line HS14
21/2” Straight Hose Quick Connect Fitting FQC12S
11/2” Male SAE J2044 Quick Connect x 3/4 ORB 08J2044-3/4UNF
1 7ft of 5/8” Fuel Line HS5807

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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. This allows for a
simple/clean installation of our products.
HOW THE CONNECTIONS WORK
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.

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ILLUSTRATION OF QUICK CONNECT COMPONENTS
IMAGE NOT TO SCALE
VIEW OF PUMP IS LOOKING DOWN
THE PORTS ARE LABELED ON THE PUMP

9
INSTALLING THE PUMP FITTINGS DF-100 & DF-165
1a-1. Dip the threaded end of the 08J2044-3/4UNF fitting into clean motor oil and
hand-thread into the “ENGINE” and “INLET” ports of the AirDog®II-5G filter base
as illustrated in figures 1, 2, and 3. Using a 3/4” deep socket, torque the fittings to
180in-lb or 15ft-lb.
1a-2. Dip the threaded end of the 06J2044716UNF fitting into clean motor oil and
hand-thread into the “RETURN” port of the the AirDog®II-5G filter base as illus
trated in figures 1 and 2. Using a 9/16” deep socket, torque the fitting to 84in-lb or
7ft-lb.
DO NOT overtighten the fittings or damage may occur!
TOOLS NEEDED:
- Torque Wrench
- 7/8” Deep Socket
- 9/16” Deep Socket
PARTS NEEDED:
- (2) 08J2044-3/4UNF Fittings
- (1) 06J2044716UNF Fitting
Figure 1
Figure 2
Figure 3
RETURN
ENGINE
INLET