PureFlow AirDog RP-100 User manual

INSTALLATION MANUAL
6.0L Ford PowerStroke
2003 THROUGH 2007
MODEL RP- 00 & RP- 50
Supplemental Lift Pump
With New Quick Connect Components!
PLEASE READ THESE INSTRUCTIONS THOROUGHLY
BEFORE BEGINNING INSTALLATION!
PureFlow AirDog
705 MAUSOLEUM ROAD
SHELBYVILLE, IN 46176 1-877-421-3187
WWW.PUREFLOWAIRDOG.COM

2
Wire Screen
Insert In Fuel Inlet
To Protect the Gerotor
Adjusta le
Regulator
Fuel Inlet
NOW
On Left Side

3
OVERVIEW
Welcome to the Raptor™ Fuel Pump
The Raptor™ Fuel Pump is a Premium supplemental lift pump for the Ford
PowerStroke 6.0L diesel engine. complete installation kit is included.
The Raptor™ output pressure for the 6.0L PowerStroke needs to be set at 10 psi at
the time of installation.
Pressure and flows are approximate as they will vary with fuel temperature and as
the brushes wear in. lso, pressures will vary with each installation due to the
differences in vehicle voltage/amp output and fuel line installation.
The Raptor™ RP-100 is recommended for stock and slightly modified 6.0L
PowerStroke Diesels. The Raptor™ RP-150 is recommended for highly modified
6.0L PowerStroke.
The Raptor™, a gerotor fuel pump, features an adjustable pressure regulator and
has a protective wire screen insert at the fuel inlet.
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THIS PUMP SUPPLIES FUEL TO THE FACTORY LIFT
PUMP.
THIS PUMP DOES NOT REPLACE THE FACTORY
LIFT PUMP!
NOTE: The pictures used in this manual are for example only and may not be exactly the
same as your truck.

4
QUICK CONNECT COMPONENT OVERVIEW
Provided in this kit are two different OE style quick connection systems. These
systems work together to allow for a quick, clean, and professional install.
Jiffy Tite Quick Connect System
Jiffy Tite’s patented quick connect system is used for the connections at theRaptor.
The images below show the flared formation of the Jiffy Tite System. Simply
insert the male end form into the fitting and push firmly until you hear it “click”
into place. To disconnect the system, use a Jiffy Tite tool similar to the image
below. This tool can be purchased at your local auto parts store. Insert the tool
into the connection and turn it ¼ turn to open the retaining spring. While the
retaining spring is open, firmly pull the connection apart.
SAE J2044 Quick Connect System
The S E J2044 quick connect system is the most commonly used system in the
automotive industry. The images below show the formation of S E 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 blue tabs on the female connector
while you firmly pull the assembly apart.

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Raptor™ 100 & 150 2003 - 2007 Ford PowerStroke
Section 1 Table of Contents
TAB E OF CONTENTS
Section 1…………………………………….………….…..Table o Contents
Section 2……………………………….……………….…..Sa ety Guidelines
Section 3……………………………….…………………….……….Parts List
INSTA ATION PROCEDURES
Section 4…………………….………….……Raptor™ & Mounting Brackets
Fuel ines
Section 5 A………………………………. Raptor™ to High-Pressure Pump
Section 5 B...…………...……………...………….… Raptor™ Suction Line
Electrical Harness
Section 6…..……………………………………….……….Electrical Harness
Section 7..………….…………………….……….…………..Final Check List

6
Raptor™ 100 & 150 2003 - 2007 Ford PowerStroke
Section 2 Installation & Safety Guidelines
Raptor™
MODEL RP-100 & RP-150
The installation o the Raptor™ Fuel Pump can be made relatively easy by ollowing
the steps outlined in this manual.
1. Inventory the package components completely. Noti y PUREFLOW
AIRDOG. immediately o any parts missing or damaged.
2. Read the installation manual and understand how the system operates be ore
beginning installation.
3. The installation recommendations contained herein are suggested installation
guidelines only. Individual installations may vary.
4. I any installation procedure is uncertain, contact PUREFLOW AIRDOG. or
technical assistance.
NOTE: SOME OF THE PICTURES USED IN THIS M NU L RE FOR
EX MPLE ONLY ND M Y NOT PICTURE COMPONENT
EX CTLY THE S ME S FOUND IN YOUR TRUCK.
SAFETY GUIDE INES!
CAUTION: Proper location o the Raptor™ on the vehicle is essential.
Consider hazards presented to the equipment by road debris and
the elements.
CAUTION: Chock the vehicle’s tires to prevent rolling.
CAUTION: Disconnect the battery cables to both batteries be ore
proceeding with the Raptor™ Fuel Pump installation.
CAUTION: Vehicle rame rails should not be drilled into or welded upon.
CAUTION: Wear sa ety glasses when operating power tools such as drills and
grinders or when using a punch or chisel.
CAUTION: Use common sense when routing uel lines and electrical
harnesses. Keep them away rom hot exhaust components and/or
moving parts. Properly secure lines to prevent cha ing.
Use Good Judgment and Common Sense When Installing the Raptor™!

7
Raptor™ 100 & 150 2003 - 2007 Ford PowerStroke
Section 3 Parts List
Parts List
QTY DESCRIPTION Part Number IM GE
1
Installation Manual
201-1-0305
1
Raptor™ RP-100
Or
RP-150
1
Frame Bracket 010-3C-0002PC
010-3C-0001PC
1 Wiring Harness 5E-2-012
1
Mounting Hardware Kit
901-61-0102-PM-RP-F
1 /4" Male Spade Connector 5D-1-08- -16/14
1
Cable Ties
5H-2-1-06/12
1 Spacer 010-3C-0003- -P
1 Suction Hose Assembly W P110-8-6-90
1 Pressure Hose Assembly W P110-8-6
1 Customer Service Oring Replacement Kit 901-05-0100
2 Push Lock Hose Splice 001-4 -1-0026
2 ¾”- 6 Oring Boss X ½” Jiffy Tite Female
Fitting
95223

8
ILLUSTRATION OF QUICK CONNECT COMPONENTS

9
Raptor™ 100 & 150 2003 - 2007 Ford PowerStroke
Section 4 Raptor™ uel Pump & Mounting Brackets
Mounting the Raptor™ to the Truck’s Frame!
The Raptor™ Fuel Pump is best mounted with the electric motor up, as shown!
4-1. Install a ¾”- 6 Oring Boss X ½” Jiffy Tite Female Fitting into the Raptor™ port
marked “IN”. Verify the wire screen insert is in place before installing the fitting.
FUEL “OUT” PORT
FUEL “IN” PORT
Figure 2
4-2. Install ¾”- 6 Oring Boss X ½” Jiffy Tite Female Fitting into the port marked “OUT”.
Properly torque the fitting.
NOTE Mounting the Raptor™ inside the frame will give more protection from road
debris.
Figure 3 Figure 4
4-3. ssemble the Raptor™ to the mounting bracket as shown in Fig. 3. Hold the assembly
next to the selected location on the frame to check for clearance . Use the spacer block to
clear fuel lines or wiring on the frame, adjust the Raptor™ up or down on the mounting
bracket as necessary.
4-4. Loose assemble the mounting bracket and pump assembly to the frame with the backing
plate using the 4” x 3/8” bolts, lock washers, and nuts. fter positioning the bracket
and pump assembly at the selected location, properly torque the fasteners.

10
Raptor™ 100 & 150 2003 - 2007 Ford PowerStroke
Section 5-A uel Lines
Fuel Line from the Raptor to the High Pressure Pump
5 -1 Remove the original factory fuel supply line at the electric OE lift pump, located on the
driver’s side inside frame rail by squeezing the tabs on the end of the connector
together. Push the quick connect fitting toward the OE lift pump while firmly
depressing the tabs. With the tabs depressed, pull the fitting assembly from the inlet
tube. Use care to hold the quick connect fitting squarely onto the inlet tube. It may be
difficult to disconnect the fitting if it becomes cocked during removal.
High Pressure Fuel Pump
With 3/8” Quick Connect Fitting
Figure 5
5 -2. ttach, by pushing, the female S E J2044 quick connect end (Figure 6) of the “Pressure
Hose ssembly” onto the factory male quick connect that was disconnected in 5 -1
(Figure 15). You will hear a “click” when properly connected.
Figure 6
5 -3. Insert the Jiffy Tite male quick connect end (see figure 7) of the “Pressure Hose
ssembly” into the female quick connect fitting previously installed in the port marked
“ENGINE”. You will hear a “click” when properly connected.
Figure 7
5 -4. ny excess fuel hose can be addressed by routing the hose in a fashion to take up the
extra length, or a section of the hose can be removed. Push lock splices have been
included if you choose to remove the excess hose.

11
Raptor™ 100 & 150 2003 - 2007 Ford PowerStroke
Section 5B uel Lines
Suction Line from the Tank to the Raptor
5B-1. Insert the male Jiffy Tite quick connect end (see figure 8) of the “Suction Hose
ssembly” to the female Jiffy Tite fitting install in the “Fuel In” port during step 4-3 of
this manual. “click” will be heard when the fitting is properly connected.
Figure 8
5B-2. Remove the original fuel suction line Quick Connect fitting from fuel tank by squeezing
the tabs on the end of the connector together. Do Not mistake the return line with the
suction line. Consult your factory manual if unsure of these procedures.
Figure 11
Figure 10
Figure 9 Suction Line Return Line
In More Detail
To release the quick-connect fitting from the fuel tank suction tube, push the fitting toward the
suction tube. With the plastic tabs firmly depressed, pull the fitting assembly from the suction
tube. Hold the Quick Connect Fitting square to the suction tube. It may be difficult to disconnect
the fitting it is cocked or becomes cocked during removal.
5B-3. ttach the other end of the “Suction Hose ssembly” to the male quick connect on the
top of the fuel module where the factory suction line was once located. “click will be
heard when the assembly is properly connected. (Figure 11)
5B-4. ny excess fuel hose can be addressed by routing the hose in a fashion to take up
the extra length, or a section of the hose can be removed. Push lock splices have
been included if you choose to remove the excess hose.

12
Raptor™ 100 & 150 2003 - 2007 Ford PowerStroke
Section 6 Electrical Harness
Figure 12
Installing the Raptor™ Fuel Pump wiring harness
Ground Wire
Hot Lead
The Raptor™ wiring harness! Water Proof Fuse
Raptor Pump Lead
Figure 13
6-1. To connect the Power Supply Lead to the Raptor™. Insert the 2 pin Deutsch connector on
the end of the wiring harness into the corresponding connector on the Raptor™.
Figure 14
6-2. Route the Raptor™ 'activation lead', to the fuse panel on the dash to the left of the
steering column. ttach spade connector into a spare fuse holder on the panel that is
“hot” when the starter key is turned to the on position. Or connect it to the High Pressure
Pump Lead.
Figure 15
6-3. Connect the Black (-) wire to an adequate ground.
BE SURE TO PROPERLY SECURE THE WIRING HARNESS TO THE VEHICLE.

13
Raptor™ 100 & 150 2003 - 2007 Ford PowerStroke
Section 7 inal Check List
INITIAL START PROCEDURE
7-1. Turn the starter key to the on/run position.
7-2. While the Raptor™ Fuel Pump is on, bleed the fuel line to the filter canister by
loosening the fuel line connection at the canister. s soon as the line is purged of air and
fuel is observed, properly tighten the fuel fitting. NOTE: put a rag or shop towel over and
around the fitting to prevent splatter. Catch all spilled fuel and dispose of properly.
7-3. Start engine!
Adjusting the Pressure Regulator
To adjust the fuel pressure, loosen the lock nut on the regulator adjustment screw. Using a flat
blade screw driver, rotate the adjustment screw clockwise to increase pressure or counter
clockwise to decrease pressure. Be careful not to loosen the regulator assembly base. If you do,
tighten it immediately. When finished, properly torque the regulator adjustment screw lock nut!
Properly tighten the adjustment screw Lock Nut when finished.
Figure 16
RECHECK ALL FUEL FITTINGS FOR LEAKAGE AND PROPERLY TORQUE AS
NECESSARY. 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.

14
PUREFLOW IRDOG
LIFETIME LIMITED EXPRESS WARRANTY
FOR
ll PureFlow irDog I, II and Raptor Systems
IMPORTANT NOTICE
TO ACTIVATE YOUR PURFLOW AIRDOG WARRANTY, YOU MUST COMPLETE AND
MAIL YOUR WARRANTY CARD TO PUREFLOW AIRDOG WITH A COPY OF YOUR
ORIGINAL SALES RECEIPT WITHIN 30 DAYS OF PURCHASE. FAILURE TO COMPLETE
AND SUBMIT YOUR WARRANTY CARD WILL RESULT IN A WARRANTY PERIOD OF
THE COVERED PRODUCE TO ONE ( ) YEAR FROM THE DATE OF PURCHASE.
PureFlow irDog (hereafter collectively, “SELLER”) warrants and guarantees only to the Original Purchaser
(hereafter collectively, BUYER) that ll PureFlow irDog Systems (hereafter collectively, PRODUCT) shall be
free from defects of materials and workmanship in the manufacturing process for as long as the BUYER owns the
PRODUCT.
The Lifetime Limited Express Warranty is limited to the PRODUCT purchased by the original BUYER of the
PRODUCT and limited solely to the parts contained within the PRODUCT and EXCLUDES LL ELSE
INCLUDING FILTERS ND W TER SEP R TORS. ny PRODUCT that is in question of Warranty must be
returned, shipped prepaid, to PureFlow irDog. ll Warranty claims are subject to the approval of PureFlow
irDog. If it is determined that a Warranty claim exists, PureFlow irDog will, at its sole discretion, replace the
defective PRODUCT with a comparable PRODUCT, repair the defective PRODUCT, or refund the BUYER”S
purchase price in exchange for the PRODUCT. Repairs or replacements are warranted for only the remainder of the
original warranty period and only to the original BUYER.
Under no circumstances shall the SELLER be liable for any labor charged or travel time incurred in the diagnosis
for defects, removal, or reinstallation of the PRODUCT, or any contingent expense.
Under no circumstances will the SELLER be liable for any damage or expense incurred by reason of the use or sale
of the PRODUCT.
Other than expressly set forth herein, the SELLER shall in no way be responsible for the proper or improper use and
service of the PRODUCT. In no event shall the SELLER be liable for any special, incidental, indirect or
consequential damages of any kind or nature, whether or not the BUYER of the PRODUCT was advised of the
possibility of damage or harm, arising or resulting from the use or performance of the PRODUCT and BUYER
hereby waives the right to any and all such claims.
BUYER, acknowledges that he/she is not relying on SELLER’S skill or judgment to select or furnish goods suitable
for any particular purpose and that SELLER has no liability that will extend beyond the scope of the LIMITED
EXPRESS W RR NTY contained herein, and BUYER hereby waives all remedies or liabilities, expressed or
implied, arising by operation of law or otherwise.(including, without limitation, any obligation of SELLER with
respect to fitness for any particular purpose; merchantability; and special, incidental, indirect or consequential
damages) or whether or not occasioned by SELLER’S negligence.
SELLER disclaims any warranty and expressly disclaims any liability for personal inquiry or damages related to
BUYER’S use of the PRODUCT. BUYER acknowledges and agrees that the disclaimer of any liability for personal
injury is a material term for this agreement and BUYER agrees to indemnify SELLER and hold SELLER harmless
from any claim related to the PRODUCT and its use or performance. Under no circumstances will SELLER be
liable for any damages, liabilities, costs or expenses incurred as a result of or by reason of use, performance or sale
of the PRODUCT, including without limitation, any damages, liabilities, costs or expenses incurred by reason of
BUYER’S negligence related to those uses of the PRODUCT.
The proper installation of the PRODUCT is the sole responsibility of the BUYER. The SELLER assumes no
liability regarding improper installation or misapplication of the PRODUCT.
SELLER hereby provides the following limited warranty as to description, quality, merchantability, fitness for the
PRODUCT’S purpose, productiveness, or any other matter of SELLER’S PRODUCT sold herewith. The SELLER

15
shall be in no way responsible for the open use and service of the PRODUCT and the BUYER hereby waives all
rights other than those expressly written herein. This Warranty shall not be extended or varied except by a written
instrument signed by SELLER and BUYER.
IN THE EVENT TH T THE BUYER DOES NOT GREE WITH THIS GREEMENT, THE BUYER M Y
PROMPTLY RETURN THE PRODUCT, IN NEW ND UNUSED CONDITION, WITH D TED PROOF
OF PURCH SE, TO THE PL CE OF PURCH SE WITHIN THIRTY (30) D YS FROM THE D TE OF
PURCH SE FOR FULL REFUND. THE BUYER GREES TH T THE INST LL TION OF THIS
PRODUCT CONFIRMS THE BUYER H S RE D ND UNDERST NDS THIS GREEMENT ND
CCEPTS THE TERMS ND CONDITIONS OF THIS GREEMENT.
Warranty Procedure
In the unlikely event a warranty appears as if it may be warranted, the following steps are taken:
1 The customer discussed the symptoms of the problem with a PureFlow AirDog Technician. The customer
is to have the system Serial Number and odel Number available for the Technician when the call is
made. This will expedite all steps of the process.
2 The customer performs any and all tests requested by the PureFlow AirDog Technician. This is done to
isolate the potential problem while eliminating potential installation or maintenance related issues,
3 If the PureFlow AirDog Technician determines based on the customer feedback concerning the requested
testing that system may be at fault, the customer is advised that all returned pumps are tested upon
arrival and should this returned pump perform at design criteria upon arrival, the customer will be
charged a $50.00 fee.
4 The PureFlow AirDog Technician will first request the customer’s phone number in the event the phone
call is accidentally disconnected and then transfer the customer to a PureFlow AirDog Customer
Service Representative. Should a Customer Service Representative not be available, the Technician
will offer the Customer the option to hold, call back, or receive a return call.
5 The PureFlow AirDog Customer Service Representative will check to determine if the customer’s Warranty
Registration Card is on file.
a. If no Warranty Registration is found, the customer will be required to supply the original
purchase receipt showing the purchase date.
b. If no Warranty Registration is found, the customer will be advised of the options should the
system in question is out of the default warranty period (1 year).
6 The PureFlow AirDog Customer Service Representative will request the customer information, including:
Name, Address, Phone Number, odel Number, Serial Number, Year / ake / odel of vehicle,
Name of Dealer purchased from, Purchase Date, Description of Problem, Customers’ understanding
of the resolution, and customer credit card information.
7 PureFlow AirDog will cover Ground Shipping charges to ship the replacement unit and will include a
prepaid shipping label for the return of the defective unit. Any additional items ordered at the time
of the replacement shipment will include their portion of the shipping cost.
8 A period of 15 Calendar Days from the time of shipment is provided for the receipt of the defective unit at
the PureFlow AirDog facility. Failure to return ship the defective unit to arrive within the defined
time period will result in a charge of $250.00 against the customer’s credit card as the purchase cost
of the defective unit.
PFT Bulletin No. 20 - -0305 Revised 8-20- 0