PureFlow AirDog FP-100 User manual

PureFlow AirDog®
AirDog® FP-100 & FP-150 1994-1998 Cummins Diesel
PROTECTED BY
CANADIAN PATENT US PATENTS AUSTRALIAN PATENT
2,108,391 5,355,860; 5,746,184; 6,729,310 2005101054
NEW ZEALAND PATENT
532356
Additional Foreign Patents Pending in Europe, South America, Mexico, Japan, and China!
#2

PureFlow AirDog®
AirDog® FP-100 & FP-150 1994-1998 Cummins Diesel
2
SMALL and COMPACT
7” Long X 3.2” Wide X 10” Tall

PureFlow AirDog®
AirDog® FP-100 & FP-150 1994-1998 Cummins Diesel
3
OVERVIEW
Welcome to PureFlow®AirDog®
Fuel Air Separation System for the Diesel Engine!
The AirDog®Fuel Air Separation system is a Premium replacement lift pump and filtration
system for the Dodge Cummins 12 Valve 5.9L diesel engine with the p-pump. A complete
installation kit is included.
The AirDog®delivers clean fuel to the engine free of virtually all air/vapor and at a positive flow.
Thus, allowing the engine “test cell” performance and efficiency, while in “real world” use.
The AirDog®FP-100 is recommended for stock and slightly modified 5.9L Cummins Diesels.
The AirDog®FP-150 is 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 control!
TYPICAL INSTALLATION LAYOUT
Figure 1
The AirDog®draws fuel from the fuel tank at constant flow, removing water, particulates,
entrained air and vapor. A regulated pressurized flow is maintained to meet the engine’s
varying fuel demands. The separated air/vapor is returned by the AirDog®to the fuel tank.
NOTE: The pictures used in this manual are for example only and may not be exactly the same
as your truck.

PureFlow AirDog®
AirDog® FP-100 & FP-150 1994-1998 Cummins Diesel
4
QUICK CONNECT COMPONENT OVERVIEW
Provided in this kit is an OE style Quick Connect 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® FP-100 & FP-150 1994-1998 Cummins Diesel
Section 1 Table of Contents
5
TABLE OF CONTENTS
Section 1....................................…………………..……..Table of Contents
Section 2…...............................................Installation & Safety Guidelines
Section 3.....................................……………….………………….Parts List
INSTALLATION PROCEDURES
Section 4……………………...………Fittings, Brackets, and Mounting
FUEL LINES
Section 5…………………………….……………Assembling the Fuel Lines
Section 6-A…………………………….………………………Fuel To Engine
Section 6-B.....................................................Engine Fuel Return to Tank
Section 6-C……………………..…...…….…..AirDog® Fuel Return to Tank
Section 6-D…………………………….……........……..Suction Line FP-100
Section 6-E………………………………….........……..Suction Line FP-150
(Includes: Hi Flow Suction Tube)
ELECTRICAL HARNESS
Section 7…..……………………………..……………….Electrical Harness
Section 8..………….……………………….……..Initial Startup Procedures
MAINTENANCE
Section 9…………………………………Filter Service Recommendations
Section 10………………………………….Cleaning the Gerotor Assembly
Section 11………………………..……..………………………….…Warranty
Lifetime Limited Express Warranty

PureFlow AirDog®
AirDog® FP-100 & FP-150 1994-1998 Cummins Diesel
Section 2 Installation and Safety Guidelines
6
AirDog®
MODEL FP-100 & FP-150
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 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. 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!
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®installation.
CAUTION! 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.
Use Good Judgment and Common Sense When Installing the AirDog®!

PureFlow AirDog®
AirDog® FP-100 & FP-150 1994-1998 Cummins Diesel
Section 3 Parts List
7
AirDog® Parts List
QTY
DESCRIPTION
Part Number
IMAGE
1
AirDog®
FP-100-D12
Or
FP-150-D12
1
AirDog®Mounting Bracket
001-3C-0004
1
Mounting Bracket Hardware Kit, Includes:
901-61-0102-PM
1
Frame Bracket Set
010-3C-0002
010-3C-0001
1
Wiring Harness
5E-2-010
1
Return Fuel Filler Tube (with 2 Clamps)
001-4A-1-0175
1
Bundle of Plastic Ties
5H-2-1-06/12
1
High Flow Suction Tube (For FP-150’s Only)
WAP108
1
Grommet (For FP-150’s Only)
5J-1-1-04-0001
1
Spacer
010-3C-0003-A-P
1
20ft of Hose
HS20
3or4
1/2” Straight Hose Quick Connect End
(3 for FP-100 Only) (4 For FP-150 Only)
FQC12S
2
1/2" 90° Hose Quick Connect End
FQC1290
1
3/8” Straight Hose Quick Connect Fitting
(For FP-100’s Only)
FQC38S
1
12mm X ½” male SAE J2044 Fitting
WAP103
1
Seal Washer (Assembles on WAP 102)
1P-5-ES
1
Customer Service Oring Replacement Kit
901-05-0101
2
1/2” Male SAE J2004 Quick Connect x 3/4” UNF
08J2044-3/4UNF
1
“P-7100” Pump Flexible Return Line
4C-1-02-05-001
2
5/16” Push Lock X ¼” Male NPT
4A-1-18-05-04
1
Injection Pump Return Tee
001-4A-1-0008

PureFlow AirDog®
AirDog® FP-100 & FP-150 1994-1998 Cummins Diesel
Section 3 Parts List
8
ILLUSTRATION OF QUICK CONNECT COMPONENTS

PureFlow AirDog®
AirDog® FP-100 & FP-150 1994-1998 Cummins Diesel
Section 4 Fittings, Brackets, and Mounting
9
Installing the AirDog®Fittings & Mounting the Bracket on the
Truck’s Frame Rail
4-1. 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!
INSTALL THE AirDog® ON THE BRACKETS AND THE TRUCK’S FRAME
4-2. 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 bolts, lock
washers, and nuts included in the mounting bracket hardware kit (figure 4). Properly
torque all fasteners! The bracket assembly should look like figure 5. You will need a
3/16” Allen and a 1/2" Wrench.
Figure 3
“Fuel In”
“Engine”
Figure 2
Figure 5
Figure 4

PureFlow AirDog®
AirDog® FP-100 & FP-150 1994-1998 Cummins Diesel
Section 4 (Continued) Fittings, Brackets, and Mounting
10
4-3. Attach the AirDog® to the frame bracket assembly as shown in figure 6 using the
supplied hardware in the mounting bracket hardware kit (P/N 901-61-0102-PM). You
will need a 3/16” Allen and a 7/16” wrench.
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.
4-4. Be sure to tuck the AirDog® as far up as possible without it rubbing on anything to
prevent damage from road debris. The bracket assembly is adjustible to achieve this.
NOTE: Be sure to direct the ‘fuel in’ port to the rear.
4-5. Clamp the frame between the AirDog® bracket assembly and the backing plate using the
3/8” x 3 ½” bolts, lock washers, and nuts included in the kit. Use two 9/16” wrenches to
tighten.
Mount
The AirDog®
Outside
The
frame
OR
Inside
The
Frame
4-6. Position the AirDog® on the frame as necessary for clearance. Properly torque the bolts
& nuts!
Figure 6
Figure 10
Figure 9
Figure 8
Figure 7
Inside of Frame
Outside of Frame

PureFlow AirDog®
AirDog® FP-100 & FP-150 1994-1998 Cummins Diesel
Section 4 (Continued) Fittings, Brackets, and Mounting
11
NOTE: Be sure to mount the AirDog® so the ‘FUEL IN’ port is directed toward the rear of the
vehicle(Figure 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® mounting bracket, you may remove part or all of it, as needed
(Figures 12 and 13). Be very careful not to damage the frame flange or fuel lines!
Vehicle Rear
Vehicle Front
Fuel In Port
Figure 11
Figure 13
Figure 12

PureFlow AirDog®
AirDog® FP-100 & FP-150 1994-1998 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 14) and
press it into the fuel line (HS20) until all three barbs are covered (Figures 15 and 16). The
fuel line end should look like Figure 16.
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 17). 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 14
Figure 16
Figure 15
Figure 17

PureFlow AirDog®
AirDog® FP-100 & FP-150 1994-1998 Cummins Diesel
Section 6-A Fuel lines (Supply Line)
13
Installing the Fuel Supply Line from the AirDog®to the
Injection Pump
When installing the AirDog®fuel system, it is recommended to bypass the factory filter
canister for optimum engine performance.
6A-1. Remove the 14mm banjo bolt and original factory fuel supply line at the fuel inlet port
of the P-7100 pump (Figure 18).
6A-2. Install the 14mm x ½” male SAE J2044 (WAP 103) fitting with the seal washer (1P-5-ES)
supplied into the inlet port of the injector pump (Figure 19) 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.
6A-3 Assemble one end of the hose (Reference section 5) using Fuel line end FQC1290 and
plug it into the WAP103 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.
Figure 18
Figure 19
WAP103
1P-5-ES
Figure 20
FQC1290
HS20
FQC12S
HS20
Figure 21

PureFlow AirDog®
AirDog® FP-100 & FP-150 1994-1998 Cummins Diesel
Section 6-B Fuel lines (Engine Fuel Return to Tank)
14
P-7100 Injector Pump and Injector Bleed Line Return to Tank
NOTE: Fuel is returned from the P-7100 fuel pump and also from the injector bleed line(s). The
original 12 Valve Cummins fuel system returns the fuel from the P-7100 injector pump directly
to the fuel tank while the injector bleed line is routed to the inlet port of the filter head to be
recycled back to the engine. When installing the AirDog®, it is best to route the fuel from the
injector bleed line back to the fuel tank as well.
6B-1. Disconnect the injector bleed line (Ref. Fig. 24) by removing the 8 mm banjo bolt. Be
careful to not misplace the O-ring washer that seals the banjo fitting.
6B-2. Disconnect and remove the 8 mm banjo fitting and
metal fuel line connecting the fuel pump to the
filter head. Either remove the line or bend it out of
the way as it will no longer be used.
6B-3. Remove the fuel filter head.
6B-4. Connect the injector bleed line banjo fitting with 8mm banjo bolt and original sealing
washers to the Return “T” Push Lock Coupler (Figure 27). The Return T Coupler is made
from 2 of the 4A-1-18-05-04 and one of the 001-4A-1-0008 (Figure 26).
6B-5. Connect the P-7100 pump metal return line to the return “T” push lock coupler fitting
with the flex fuel line P/N 4C-1-02-05-001 (Figure 28).
Figure 22
Figure 23
Figure 25
Figure 26
Figure 27
Figure 28
Figure 24
End of steel line from the
P-7100 that connects to
the tank return line.
Injector Bleed Line that
connects to the tank return
line.
Return Line From the
P-7100 Pump

PureFlow AirDog®
AirDog® FP-100 & FP-150 1994-1998 Cummins Diesel
Section 6-B (Continued) Fuel lines (Engine Fuel Return to Tank)
15
P-7100 Injector Pump and Injector Bleed Line Return to Tank,
Continued
6B-6. Cut the original fuel return line to length and connect
it to the other end of the Return “T” Push Lock
Coupler fitting.
NOTE: The mechanical fuel lift pump must be disabled by removing the plunger.
6B-7. Remove the mechanical lift pump by removing the two bolts on each side of the pump.
Remove the plunger. Be very careful. DO NOT drop the plunger into the oil pan.
Block Off Plate
(Not Included In Kit)
6B-8. Either re-install the pump on the engine without the plunger or cover the mechanical
pump port on the engine with a Big Block Chevy pump “block off” plate from your local
auto parts store (Figure 31).
Figure 29
Figure 30
Figure 32
Figure 31

PureFlow AirDog®
AirDog® FP-100 & FP-150 1994-1998 Cummins Diesel
Section 6-C Fuel lines (AirDog® Fuel Return to Tank)
16
AirDog®Fuel Return Line
Installing the fuel 'Return to Tank' assembly in Filler Tube
6C-1. Cut filler tube as illustrated in figure 33, removing ½inch of hose. Loose assemble
clamps on each end of filler tube before the filler tube is pushed in.
6C-2. Insert the “Return Fuel Filler Tube” assembly (P/N 001-4A-1-0175) in the filler tube.
INSTALL THE FILLER TUBE WITH ARROWS, WHICH ARE STAMPED IN THE PART,
POINTING TOWARD THE TANK!! SEE FIG 34. Properly tighten clamps.
6C-3. Assemble one end of the hose (Reference section 5) using Fuel line end FQC1290 and
plug it into the “Return” J2044 fitting installed in the AirDog® (Figure 36). A “click” will
be heard once the fitting is properly connected.
6C-4. Run the fuel line along the frame as mentioned in step 5-3 to the filler neck tee. 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 filler neck tee (001-4A-1-0175). A
“click” will be heard once properly connected.
HS20
Fuel Tank
Hose Clamp
Filler
Tube
Fuel
Figure 33
Figure 35
Figure 34
Towards
Tank
Figure 36
FQC1290
HS20
FQC12S
HS20
Figure 37

PureFlow AirDog®
AirDog® FP-100 & FP-150 1994-1998 Cummins Diesel
Section 6-D Fuel lines (Suction Line from Tank FP-100)
17
Fuel Suction Line for AirDog®FP-100
NOTE: The AirDog®FP-150 requires a High Flow Suction Tube. If you are installing an AirDog®FP-
150 skip Section 6-D and go to section 6-E for these installation instructions.
Connecting the Fuel Supply Line from the Tank to AirDog®FP-100
6D-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.
6D-2. Assemble one end of the hose (Reference section 5) 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.
6D-3. Run the fuel line along the frame as mentioned in step 5-3 to the AirDog® “Fuel In” port.
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 in the AirDog® “Fuel In” port.
A “click” will be heard once properly connected.
Suction Line
(The larger
of the two)
Return Line
Figure 38
Figure 39
FQC38S
HS20
Figure 40
FQC12S
HS20
Figure 41

PureFlow AirDog®
AirDog® FP-100 & FP-150 1994-1998 Cummins Diesel
Section 6-E Fuel lines (Suction Line from Tank FP-150)
18
Fuel Suction Line for AirDog®FP-150
6E-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.
HIGH FLOW SUCTION TUBE
6E-2. Either remove the bed or drop the tank for access to the collection basket.
The AirDog®150 includes a 1/2” High Flow suction tube (P/N WAP108) to accommodate
the high flows of this system. To install the 1/2" suction tube, it is necessary to either drop the
fuel tank or to lift the truck bed.
NOTE: Should you choose to drop the fuel tank, support the tank as it is when it is installed on
the truck. If you let it rest flat on the floor, the tank may squash out and the suction tube will be
too short after the tank is re-installed in the truck. The suction tube, being cut too short may
suck air as the fuel drops below 1/4 tank level.
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 45
Figure 44
Figure 43
FQC12S
HS20
Figure 42

PureFlow AirDog®
AirDog® FP-100 & FP-150 1994-1998 Cummins Diesel
Section 6-E (Continued) Fuel lines (Suction Line from Tank FP-150)
19
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.
IMPORTANT: Select a location for the suction tube that has adequate clearance below the bed.
Also consider that under hard acceleration, fuel will migrate toward the back of the fuel tank.
6E-3. Once either the tank has been dropped or the bed removed, remove the collection
basket as shown in figures 48 and 49.
Figure 47
Figure 46
Figure 49
Figure 48

PureFlow AirDog®
AirDog® FP-100 & FP-150 1994-1998 Cummins Diesel
Section 6-E (Continued) Fuel lines (Suction Line from Tank FP-150)
20
6E-4. Drill a 1-1/8” hole at the selected location (Figure 50) in the fuel tank for the suction
tube. Hold a container below the drill point to catch debris as shown in figure 51.
6E-5. Remove all burrs from the edge of the hole as shown in figure 52.
6E-6. Install the grommet (P/N 5J-1-1-04-0001) in the new suction tube access hole as seen in
figure 53.
6E-7. Measure and cut the suction tube to a length that will allow approximately 1/8”
clearance off the bottom of the tank. It is suggested to form the end of the tube similar
to Figure 54.
Figure 51
Figure 50
Figure 52
Figure 53
Figure 54