PureFlow AirDog FP-100-4G User manual

FP-100-4G
FP-150-4G
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
#3
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 6
QUICK CONNECT FITTING ILLUSTRATION 7
PUMP TO FRAME INSTALLATION 8
PUMP CRADLE BRACKET INSTALLATION 9
PUMP TO FRAME INSTALLATION 10
FUEL LINE ASSEMBLY OVERVIEW 12
ENGINE LINE INSTALLATION VP-44 13
ENGINE LINE INSTALLATION CP3 15
FUEL FILTER HOUSING REMOVAL 16
RETURN LINE INSTALLATION 17
INLET LINE INSTALLATION FP-100 18
INLET LINE INSTALLATION FP-150 20
WIRING INSTALLATION 27
INITIAL STARTING PROCEDURE 30
FILTER SERVICE 31
SERVICING THE PUMP GEROTOR 32
WARRANTY 33

2
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 Original AirDog® uses a ball and spring on the return side of the pump to
regulate fuel pressure. The pressure for this application is 15-17psi. The fuel pressure
is not adjustible other than stretching the spring for higher pressure or cutting the
spring for lower pressure. If a different fuel pressure is desired, call 317-421-3180 and
speak to an AirDog® Technician. We may have the pressure spring you are looking for.
OVERVIEW ON HOW THE SYSTEM OPERATES
The AirDog® draws fuel from the tank from the factory suction fitting in the
moduel for the FP-100 and from a high flow suction tube for the FP-150 and FP-100
with the In-Tank fuel pump. The fuel is then pulled through a water separator before
being pressurized through the Gerotor pump. The pressureized fuel is sent through the
2 micron fuel filter before being sent to the engine. The pump maintains pressure
through a high flow ball and spring regulator behind the tank fitting in the filter base.

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
QTY DESCRIPTION PART NUMBER IMAGE
1 AirDog® FP-100 OR FP-150
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
1High Flow Suction Tube WAP109
1 1.5” Filler Neck Tee with Clamps 001-4A-1-0150
1 20ft of Fuel Line HS20
3 or 4
1/2” Straight Hose Quick Connect Fitting
(3 for FP-100 Only) (4 for FP-150 and
FP-100 with In Tank Pump Only)
FQC12S
21/2” 90deg Hose Quick Connect Fitting FQC1290
13/8” Straight Hose Quick Connect Fitting
(For FP-100 Only) FQC38S
2 or 3
1/2” Male Quick Connect x 3/4-16 UNF ORB
(2 for FP-100 Only) (3 for FP-150 and
FP-100 with In Tank Pump Only)
08J2044-3/4UNF
112mm x 1/2” male SAE J2044 Injection
Pump Fitting WAP102
1 12mm Sealing Washer for WAP103 1P-5-DS
1 Zip/Cable Tie Bundle 5H-2-1-B
1 Customer Service O-ring Kit 901-05-0103
(For FP-150 and
FP-100 with In Tank Pump Only)
PARTS LIST
1 Vacuum Cap (FP-150 & FP-100 with in-tank pump) HVC-467-16
1Vacuum Cap Hose Clamp(FP-150 & FP-100 with in-tank pump) 4C-2-1-10

6
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.

7
ILLUSTRATION OF QUICK CONNECT COMPONENTS
IMAGE NOT TO SCALE
VIEW OF PUMP IS LOOKING
DOWN
THE PORTS ARE LABELED

8
INSTALLING THE PUMP FITTINGS
1-1. Dip the threaded end of the 1/2” male J2044 quick connect x 3/4” UNF fittings
(08J2044-3/4UNF) into clean motor oil and hand-thread into the “ENGINE” and
“FUEL IN” ports in the AirDog®. Using a 7/8" deep socket, torque these fittings to
180in-lb or 15ft-lb.
DO NOT overtighten the fittings or damage may occur!
“ENGINE” “FUEL IN”
TOOLS NEEDED:
- Torque Wrench
- 7/8” Deep Socket
PARTS NEEDED:
- (2) 08J2044-3/4UNF fittings
Figure 1

9
INSTALLING THE PUMP ON THE BRACKET
TOOLS NEEDED:
- 3/16 Allen
- 7/16 Socket or Wrench
PARTS NEEDED:
- (4) 1/4-20 x 1.25 Socket Head Cap Screws
- (4) 1/4” Lock Washers
- (4) 1/4-20 Nuts
- (1) 001-3C-0004 Cradle Bracket
2-1. First, take a look under the truck and pick a location where the pump and
brackets will fit. Once the location is known, orient the pump in the cradle bracket
with the suction line “FUEL IN” pointed towards the fuel tank.
We do recommend mounting the system on the inside of the
frame if possible.
2-2. Using the above listed hardware, mount the AirDog to the cradle bracket in the
desired orientation using a 7/16 socket and 3/16 Allen wrench.
Figure 2
Figure 3

10
INSTALLING THE PUMP ON THE FRAME
TOOLS NEEDED:
- 3/16 Allen
- 1/2 Socket or Wrench
- 9/16 Socket or Wrench x2
PARTS NEEDED:
- (4) 5/16-18 x 3.0” Flat Socket Head Cap Screws
- (4) 5/16” Lock Washers
- (4) 5/16-18 Nuts
- (3) 3/8-16 x 4.5” Hex Head Cap Screw
- (3) 3/8 Lock Washers
- (3) 3/8-16 Nuts
- (1) 010-3C-0001 Front Frame Sandwich Plate (Multiple Holes)
- (1) 010-3C-0002 Back Frame Sandwich Plate
- (1) 010-3C-0003-A-P Spacer Block
3-1. Mock up the Front Frame Sandwich Plate (Multiple Holes) (010-3C-0001) on the
frame and hold the pump assembly up to it. Choose a set of holes that tucks the
pump up as far as possible without touching the bottom of the cab and use those
holes to mount the pump in the next step.
Figure 4
THE PUMP IN THE PHOTO IS A 5G, BUT THE
CONCEPT IS THE SAME

11
INSTALLING THE PUMP ON THE FRAME CONTINUED
3-2. 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 3 using
the four 5/16 bolts, lock washers, and nuts included in the mounting bracket
hardware kit (figure 5). Using a 3/16” Allen and a 1/2“ wrench, properly torque all
fasteners!
3-3. Clamp the frame between the AirDog® bracket assembly and the backing plate
using the 3/8” x 4 ½” bolts, lock washers, and nuts included in the kit. Use two
9/16” wrenches to tighten.
Figure 5
Figure 6

12
FUEL LINE ASSEMBLY OVERVIEW
This kit includes a length of fuel line and separate fuel line fittings to allow for a
much cleaner looking installation. Assemble the fuel lines as you install them.
Do not pre-assemble the fuel lines, or the lengths will not be
correct.
4-1. Take the fuel line end and lubricate the barbed end with clean motor oil (Figure
7) and press it into the fuel line (HS20) until all three barbs are covered (Figures
8 and 9). The fuel line end should look like Figure 9.
4-2. 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.
4-3. Run the fuel line along the frame away from any hot or moving parts such as
exhaust or the driveshaft (Figure 10). 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 4-1.
Hose clamps are not needed for these push-lock connectors. They
may casue damage to the hose and cause fuel leaks.
Figure 7 Figure 8 Figure 9
Figure 10

13
ENGINE LINE INSTALLATION VP-44 98.5-02
When installing the AirDog® fuel system, it is recommended to
bypass the factory filter canister for optimum engine performance.
5a-1. Remove the 12mm banjo bolt and original factory fuel supply line at the fuel inlet
port of the VP-44 pump with a 17mm wrench (Figure 11).
5a-2. Install the 12mm x ½” male SAE J2044 (WAP 102) fitting with the seal washer
(1P-5-DS) supplied into the inlet port of the injector pump (Figure 12) using a
13/16” Wrench. Do not over tighten the fitting. It may crack or break. Either
remove or bend the original supply line out of the way.
TOOLS NEEDED:
- 13/16” Wrench or Extra Deep Socket
- Clean Motor Oil or ATF
- Hose Cutters or a way to cut Fuel Line
- 17mm Wrench
PARTS NEEDED:
- (1) WAP102 Injection Pump Fitting
- (1) 1P-5-DS Sealing Washer
- (1) FQC12S 1/2” Straight Quick Connect Fitting
- (1) HS20 20ft Fuel Line
Figure 12
Figure 11

14
ENGINE LINE INSTALLATION VP-44 98.5-02 CONTINUED
5a-3. Assemble one end of the hose (Reference section 4) 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.
5a-4. Run the fuel line along the frame as mentioned in step 4-3 to the “Engine” port in
the AirDog®. Cut the fuel line to length and insert fuel line end FQC12S per step
4-1. 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.
HS20 FQC12S Figure 14
FQC1290
HS20
Figure 13

When installing the AirDog® fuel system, it is recommended to
bypass the factory filter canister for optimum engine performance.
5a-1. Remove the 12mm banjo bolt and original factory fuel supply line at the fuel inlet
port of the VP-44 pump with a 17mm wrench (Figure 11).
5a-2. Install the 12mm x ½” male SAE J2044 (WAP 102) fitting with the seal washer
(1P-5-DS) supplied into the inlet port of the injector pump (Figure 12) using a
13/16” Wrench. Do not over tighten the fitting. It may crack or break. Either
remove or bend the original supply line out of the way.
15
ENGINE LINE INSTALLATION CP3 03-04
When installing the AirDog® fuel system, it is recommended to
bypass the factory filter canister for optimum engine performance.
5b-1. Using a 17mm wrench, remove the “banjo bolt” (Highlighted in Figure 15) and the
original factory fuel supply line at the fuel inlet port of the CP-3 high pressure
pump.
5b-2. Install the 12mm x ½” male SAE J2044 (WAP 102) fitting with the seal washer
(1P-5-DS) supplied into the inlet port of the injector pump (Figure 16) using a
13/16” wrench. Do not over tighten the fitting. It may crack or break. Either
remove or bend the original supply line out of the way.
5b-3. Refer to steps 5a-3 and 5a-4 to install the fuel supply line from the CP3 to the
AirDog®.
WAP102
1P-5-DS
Figure 15
Figure 16

16
FUEL FILTER HOUSING REMOVAL
It is not necessary to remove the fuel filter housings on these trucks. At the
most, the line from the filter housing to the injection pump will need to be
removed with a 17mm wrench.
6-1. The Filter Housing can be removed on the 98.5-02 VP-44 trucks as it is no longer
used.
6-2. To remove the filter housing on the 03-04 CP3 trucks, you will need to buy a filter
bypass as the engine return runs back through the filter housing. Follow the
directions from the filter bypass kit you purchase for installation.
6-3. To remove the filter housing on the VP-44 trucks, remove the two(2) bolts from
the top of the filter housing using a 10mm wrench/socket and remove the inlet
and outlet banjo bolts with a 17mm wrench. You will either need to shorten the
two removed 10mm bolts and reinstall them in the intake plenum or source
shorter bolts and install them.
The filter housing shown in Figure 17 is from a 98.5-00 VP-44. The
01-02 Filter housing has the inlet going to the bottom of the
housing.
Figure 17

17
RETURN LINE INSTALLATION
7-1. Cut the filler tube as illustrated in figure 18. Loose assemble clamps on each end
of filler tube before the return tee (001-4A-1-0150) is pushed in. Install the filler
return tee with the arrows pointing towards the fuel tank (figure 19). Failure to do
so will cause fuel to spray up the filler tube and not down it. The finished product
should look like figure 20.
7-2. Assemble one end of the hose (Reference section 4) using Fuel line end
FQC1290 and plug it into the “Return” J2044 fitting installed in the AirDog®
(Figure 21). A “click” will be heard once the fitting is properly connected.
7-3. Run the fuel line along the frame as mentioned in step 4-3 to the filler neck tee.
Cut the fuel line to length and insert fuel line end FQC12S per step 4-1. Once the
connector is installed, connect it to the male J2044 fitting in the filler neck tee
(001-4A-1-0150). A “click” will be heard once properly connected.
TOOLS NEEDED:
- Clean Motor Oil or ATF
- Hose Cutters or a way to cut Fuel Line and the Filler Neck
PARTS NEEDED:
- (1) 001-4A-1-0150 1.5” Filler Neck Return Tee with Clamps
- (1) FQC1290 1/2“ 90deg Quick Connect Fitting
- (1) FQC12S 1/2” Straight Quick Connect Fitting
- (1) HS20 20ft Fuel Line
Towards
Tank
Figure 18 Figure 19 Figure 20
HS20
FQC1290
Figure 21
HS20 FQC12S Figure 22

18
INLET LINE INSTALLATION FP-100 WITHOUT IN TANK PUMP
The AirDog® FP-150 requires a High Flow Suction Tube! If you
are installing an AirDog® FP-150, skip Section 8 and go to section
9 for the installation instructions.
8-1. Remove the original fuel suction line Quick Connect fitting from fuel tank by
squeezing the tabs on the end of the connector together and removing the
factory suction line connection. Consult factory manual if unsure. Very
Important: After removing the factory line check to make sure that the blue
plastic retainer was removed with the line. If the blue retainer remained attached
to the tank tube, it MUST be removed before the new fuel line Quick Connect will
connect and seat to the tank suction tube. The original suction line can be tied
out of the way or removed.
8-2. Assemble one end of the hose (Reference section 4) using fuel line end
FCQ38S and plug it into the male connection to where the factory suction line
was just removed in the previous step. A “click” will be heard once properly
connected
TOOLS NEEDED:
- Clean Motor Oil or ATF
- Hose Cutters or a way to cut Fuel Line
PARTS NEEDED:
- (1) FQC38S 3/8“ Straight Quick Connect Fitting
- (1) FQC12S 1/2” Straight Quick Connect Fitting
- (1) HS20 20ft Fuel Line
Suction Line
(The larger of
the two Return Line
Figure 23
HS20 FQC38S
Figure 24

19
7-1. Cut the filler tube as illustrated in figure 18. Loose assemble clamps on each end
of filler tube before the return tee (001-4A-1-0150) is pushed in. Install the filler
return tee with the arrows pointing towards the fuel tank (figure 19). Failure to do
so will cause fuel to spray up the filler tube and not down it. The finished product
should look like figure 20.
7-2. Assemble one end of the hose (Reference section 4) using Fuel line end
FQC1290 and plug it into the “Return” J2044 fitting installed in the AirDog®
(Figure 21). A “click” will be heard once the fitting is properly connected.
7-3. Run the fuel line along the frame as mentioned in step 4-3 to the filler neck tee.
Cut the fuel line to length and insert fuel line end FQC12S per step 4-1. Once the
connector is installed, connect it to the male J2044 fitting in the filler neck tee
(001-4A-1-0150). A “click” will be heard once properly connected.
INLET LINE INSTALLATION FP-100 WITHOUT IN TANK PUMPC ONTINUED
8-3. Run the fuel line along the frame as mentioned in step 4-3 to the AirDog® “Fuel
In” port. Cut the fuel line to length and insert fuel line end FQC12S per step 4-1.
Once the fuel line end is pressed in, connect it to the male J2044 fitting in the
AirDog® “Fuel In” port. A “click” will be heard once properly connected.
Figure 25 FQC12S HS20