Installation Manual
Contents
1. FUEL PREPORATOR INSTALLATION MANUAL 8 MODEL FP 100 amp FP 150 With New Quick Connect Components 2003 2007 FORD POWERSTROKE 6 0L DIESEL ENGINE PLEASE READ THESE INSTRUCTIONS THOROUGHLY BEFORE BEGINNING INSTALLATION PureFlow AirDog E USA 705 MAUSOLEUM ROAD u SHELBYVILLE IN 46176 1 877 421 3187 www pureflowairdog com 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 PB ou bd ize tuac ex PureFlow Diesel System ETE wu F on Gar u be M n ter 60 amp 6 746 184 23 RIN y PULL SEPRRATIOK ETSTEM Daie ci Fergan Parnis Fancng aU MODEL NO FP 150 Voszasss Pawi Preparato SMALL and COMPACT 7 Long X 3 2 Wide X 10 Tall OVERVIEW Welcome to PureFlow AirDog Fuel Air Separation Filtration and Delivery System for the Diesel Engine The AirDog Fuel Air Separation system is a Premium lift pump and filtration system for the Ford PowerStroke 6 0L diesel engine 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 1 real world use The AirDog FP 100 flows 100 GPH and is recommended for2. 17 AirDog FP 100 amp FP 150 Ford PowerStroke 2003 2007 6 0L Section 6 Electrical Harness The AirDog is equipped with a relay controlled wiring harness WIRING DIAGRAM In Red Dash Plate Fuel Line indicator Light m umm Return To Tank Fuel Tank Filler Tube High Pressure Fuel Pump Figure 60 The AirDog wiring harness AirDog Pump Motor Lead Pressure Sensor Switch Lead Indicator Light Lead Battery Positive Lead Battery Negative Lead Mini Fuse Tap Relay Lead Figure 61 CAUTION If the OPTIONAL Low Pressure Indicator Light is not used be sure to insulate the two 2 10 Indicator Light connectors to prevent accidental contact Securing the Relay and Fuse Holder to the Vehicle 6 1 Secure the relay and fuse holder to the vehicle Figure 62 Figure 63 18 AirDog FP 100 amp FP 150 Ford PowerStroke 2003 2007 6 0L Section 6 Electrical Harness Connecting the AirDog Relay Control Lead 6 2 Route the AirDog Relay activation lead to the fuse panel on the dash to the left of the steering column Insert the mini fuse tap into a spare fuse holder on the panel that Figure 65 6 3 Route the AirDog Relay activation lead the Red wire with the mini fuse tap attached to the OE fuel pump Remove the mini fuse tap and splice the relay lead to the OE fuel pump lead NOTE The power supply leads can be connected to the battery or the alternator Connecting the power suppl
3. or misapplication of the PRODUCT 24 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 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 THAT THE BUYER DOES NOT AGREE WITH THIS AGREEMENT THE BUYER MAY PROMPTLY RETURN THE PRODUCT IN A NEW AND UNUSED CONDITION WITH A DATED PROOF OF PURCHASE TO THE PLACE OF PURCHASE WITHIN THIRTY 30 DAYS FROM THE DATE OF PURCHASE FOR A FULL REFUND THE BUYER AGREES THAT THE INSTALLATION OF THIS PRODUCT CONFIRMS THE BUYER HAS READ AND UNDERSTANDS THIS AGREEMENT AND ACCEPTS THE TERMS AND CONDITIONS OF THIS AGREEMENT Warranty Procedure In the unlikely event a warranty appears as if it may be warranted the following steps are taken 1 Thecustomer discussed the symptoms of the problem with a PureFlow AirDog Technician The customer is to have the system Serial Number and Model 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 eliminatin
4. 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 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 Ri Cod Figure 29 Figure 30 Figure 31 If you choose to remove the bed properly support the truck bed to prevent serious injury or death Figure 32 Figure 33 14 PureFlow AirDog AirDog FP 100 amp FP 150 Ford PowerStroke 2003 2007 6 0L Section 5 D High Flow Suction Tube INSTALLING THE HIGH FLOW SUCTION TUBE Cont d 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 5D 1 Remove the collection basket Figure 34 Figure 35 5D 2 Drill a 1 1 8 hole at the selected location in the fuel tank for the suction tube Hold a container below the drill point to catch debris Figure 36 Figure 37 5D 3 Remove all burrs from the edge of the hole Figure 38 Figure 39 5D 4 Install the grommet in the new suction tube access hole 15
5. 2 PM F 010 3C 0002PC Frame Bracket 010 3C 0001PC NN NE E 3 Return Fuel Filler Tube with 2 Clamps 001 4A 1 0150 1 Bundle of Plastic Ties 5H 2 1 06 12 WAP108 l High Flow Suction Tube For FP 150 s Only Grommet For FP 150 s Only 5J 1 1 04 0001 Oo nm Suction Hose Assembly For FP 100 Only WAP110 8 6 90 1 Suction Hose Assembly For FP 150 Only WAP110 8 8 90 Return Hose Assembly WAP110 8 8 90 a Pressure Hose Assembly WAPI10 8 6 gQ Customer Service Oring Replacement Kit 901 05 0101 BEEN m Push Lock Hose Splice 001 4A 1 0026 m 1 2 Male SAE J2004 Quick Connect x 3 8 NPTF 08J2044 3 8 NPTF E ILLUSTRATION OF QUICK CONNECT COMPONENTS TO WAP 110 8 8 90 001 4A 1 0150 FP 150 WAPIOS WAPI10 8 8 90 PRE INSTALLED FROM FACTORY 08J2044 3 8NPTF FOR FP 100 WAP 110 8 6 90 FOR FP 150 WAP 110 8 8 90 FUEL IN ENGINE WAPI 10 8 6 08J2044 3 8NPTF AirDog FP 100 amp FP 150 Ford PowerStroke 2003 2007 6 0L Section 4 AirDog Mounting Brackets Installing the AirDog amp Mounting Brackets on the Truck s Frame E Figure 2 Figure 3 Figure 4 4 Assemble the AirDog mounting bracket to the frame bracket Use the spacer block to adjust the AirDog to clear lines and wiring harnesses on the frame Also adjust the assembly up or down on the frame bracket as needed for clearance Figure 7 Figure 5 NGINE 4 2 I
6. DS OR DAMAGE THE FILTER SEAL 3 To prime the filter turn the ignition switch to the on position Start the engine Water Separator With the engine turned off pinch off the suction line Open valve on the bottom of the water separator Drain into a suitable container until all water has been removed Close valve Remove the pinch in the suction DRAINING The water separator should be serviced once a month or when severe water in fuel conditions require NOTE Collect all spilled fuel and dispose of in accordance with federal state and local regulations 25 PUREFLOW AIRDOG LIFETIME LIMITED EXPRESS WARRANTY FOR Covered PureFlow AirDog 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 1 YEAR FROM THE DATE OF PURCHASE PureFlow AirDog hereafter collectively SELLER warrants and guarantees only to the Original Purchaser hereafter collectively BUYER that All PureFlow AirDog 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 th
7. PureFlow AirDog AirDog FP 100 amp FP 150 Ford PowerStroke 2003 2007 6 0L Section 5 D High Flow Suction Tube INSTALLING THE HIGH FLOW SUCTION TUBE Cont d 5D 5 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 40 Figure 40 5D 6 Lubricate the bulkhead fitting with motor oil Pressing firmly insert the suction tube assembly into the grommet Be sure the bulkhead fitting 1s completely seated 1 the grommet Figure 41 Figure 42 5D 7 Re install the Collection basket Re install the factory return line to the proper port of the Collection basket before the tank is fully re installed Figure 43 5D 8 Connect the end of the Suction Hose Assembly to the bulk head fitting while it is easily accessible A click will be heard when it is properly installed 5D 9 Any 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 16 PureFlow AirDog AirDog FP 100 amp FP 150 Ford PowerStroke 2003 2007 6 0L Section 5 D High Flow Suction Tube INSTALLING THE HIGH FLOW SUCTION TUBE Cont d 5D 10 If the fuel tank was dropped to install the suction tube re install the fuel tank If the truck bed was removed reinstall the bed
8. Return Fuel Filler Tube assembly in filler tube INSTALL THE FILLER TUBE WITH ARROWS POINTING TOWARD THE TANK SEE FIG 22 Properly tighten clamps SB 3 Insert the SAE J2044 female quick connect end see Figure 23 of the Return Hose Assembly into the pre installed male fitting in the port marked Tank The fitting will click when properly installed 5B 4 Attach the other end of the Return Hose Assembly onto the male end form of the Return Fuel Filler Tube installed in step 5B 2 A click will be heard when the fitting 1s properly connected 5B 5 Any 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 AirDog FP 100 amp FP 150 Ford PowerStroke 2003 2007 6 0L Section 5 C Fuel Lines Section 5 C 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 5 C and go to section 5D 5D 1 Insert the female quick connect end see figure 24 of the Suction Hose Assembly to the male fitting installed in the Fuel In port during step 4 3 of this manual A click will be heard when the fitting 1s properly connected 7 1 Figure 24 5C 2 Remove the original fuel suction line Quick Connect fitting from fuel tank by squeezing the tabs on th
9. e PRODUCT and limited solely to the parts contained within the PRODUCT and EXCLUDES ALL ELSE INCLUDING FILTERS AND WATER SEPARATORS Any PRODUCT that is in question of Warranty must be returned shipped prepaid to PureFlow AirDog All Warranty claims are subject to the approval of PureFlow AirDog If it is determined that a Warranty claim exists PureFlow AirDog will at its sole discretion replace the defective PRODUCT with a comparable PRODUCT repair the defective PRODUCT or refund the 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 cla
10. e 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 27 p Figure 25 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 5C 3 Attach the other end of the Suction Hose Assembly to the male quick connect on the top of the fuel module where the factory suction line was once located A click will be heard when the assembly 15 properly connected Figure 27 5C 4 Any 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 13 AirDog FP 100 amp FP 150 Ford PowerStroke 2003 2007 6 0L Section 5 D Fuel Lines INSTALLING THE AIRDOG FP 150 HIGH FLOW SUCTION TUBE The AirDog 150 includes a 4 High Flow suction tube 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
11. fittings especially the quick connect at the tank 20 AirDog FP 100 amp FP 150 Ford PowerStroke 2003 2007 6 0L Section 8 Fuel Filter amp Water Separator Filter Service Recommendations Plugging of either the fuel filter or the water separator itself will cause low fuel pressure and low flow to the engine If a low fuel pressure issue exists replace the fuel filter AirDog 2 Micron Fuel Filter AirDog WATER SEPARATOR Drain Valve The Water Separator Replace the water separator every other time you change the Fuel Filter or if it becomes damaged or plugged It is suggested to check drain the water separator every three months or as needed should you experience excessive water in fuel conditions When installing the water separator be sure to clean the underside of the AirDog base Follow the instructions printed on the pre filter for proper tightening procedures CAUTION Be extremely careful to prevent any contaminates or debris from entering the pre filter when removing it for cleaning Large debris will jam the Gerotor and cause the fuse to blow This is not a warranty item Should this happen you can easily put the system back into working order See the instructions on How to clean the Gerotor for proper procedures The Fuel Filter Remove the fuel filter by turning it counter clockwise Do Not pre fill the fuel filter with fuel The AirDog will fill the filter and prime the system automatically Fo
12. g potential installation or maintenance related issues 3 Ifthe 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 Ifno Warranty Registration is found the customer will be required to supply the original purchase receipt showing the purchase date b Ifno 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 Model Number Serial Number Year Make Model of vehicle Name of Dealer purchased from Purchase Date Description of Problem Customers understa
13. ile you firmly pull the assembly apart AirDog FP 100 amp FP 150 Ford PowerStroke 2003 2007 6 0L Section 1 Table of Contents TABLE OF CONTENTS Section Wad Table of Contents Installation and Safety Guidelines Section 3 a M Parts List INSTALLATION PROCEDURES Section 4 E B S AirDog amp Mounting Brackets FUEL LINES Section 5 A A WV F B QS Fuel To High Pressure Pump Section 5 B i MMB F E IRA Fuel Return to Tank Section 59K M F F R ab ouction line For FP 100 Section ea E Aa a a RE Suction Line For FP 150 Includes Hi Flow Suction Tube ELECTRICAL HARNESS Section 6 2 0 cece cece cece cc ec nn Electrical Harness Section my rre nsn nnne nnn sens Final Check List MAINTENANCE Section ks csse Filter Service Recommendations Section ko sess Cleaning the Gerotor Assembly AirDog FP 100 amp FP 150 Ford PowerStroke 2003 2007 6 0L Section 2 Installation amp Safety Guidelines AirDog MODEL FP 100 amp 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 i
14. ims 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 WARRANTY 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
15. llow the instructions on the filter for proper tightening procedures CAUTION Dispose of waste fuel and used filters properly to protect OUR environment 21 AirDog FP 100 amp FP 150 Ford PowerStroke 2003 2007 6 0L Section 9 AirDog Fuel Pump Cleaning Foreign Debris from the Gerotor Assembly Step 1 Step 2 Step 3 Remove the four 4 socket Carefully remove the O ring Remove and clean the gerotor head cap crews that secure you will need to re use it Be very careful not to damage the gerotor cap the gerotor Step 4 Step 5 Step 6 Clean the inside of the Replace the O ring and Align the teeth and gerotor pocket center gear install the outer gear Step 7 Step 8 Install the gearotor cap Be very Replace the cap into careful to index the cap to position position Be very careful the wide space between the half do not pinch the O ring moon cuts to the bottom Torque the cap screws in an opposing pattern 72 Installing a New Filter 1 Clean the area around the filter head and groove or seal area NOTE Lubricate the seal with oil Do not use diesel fuel to lubricate the seal 2 Install a new fuel filter on the filter head Turn clock wise until the filter contacts the seal Tighten the filter one full turn or follow tightening instructions on filter after contact with the seal has been made NOTE It is not necessary to pre fill the fuel filter CAUTION DO NOT OVER TIGHTEN OVER TIGHTENING CAN DISTORT THREA
16. nding 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 ADI F0307 P 100 150 Revised July 24 2014 23
17. ng 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 15 SA 2 Attach by pushing the female SAE J2044 quick connect end Figure 16 of the Pressure Hose Assembly onto the factory male quick connect that was disconnected in 5 Figure 15 You will hear a click when properly connected Figure 16 5A 3 Insert the female quick connect end see figure 17 of the pressure hose assembly into the male quick connect fitting previously installed in the port marked ENGINE You will hear a click when it connects Figure 17 5A 4 Any 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 1 AirDog FP 100 amp FP 150 Ford PowerStroke 2003 2007 6 0L Section 5 B Fuel Lines Fuel Return Line from the AirDog to the Tank Installing the fuel Return to Tank assembly in Filler Tube Ss Filler 4 Tube N i F4 Hose Clamp Fuel Tank Figure 21 5B 1 Cut filler tube as illustrated removing 12 inch Loose assemble clamps on each end of filler tube Figure 22 Figure 23 5B 2 Insert
18. nstall a 1 2 Male SAE J2004 Quick Connect x 3 8 08J2044 3 8NPTF into ENGINE and FUEL IN ports in the AirDog the Figure 8 WARNING The NPT fitting threads must be lubricated with oil or anti seize compound before installation to prevent galling NOTE The AirDog can be mounted on either the outside of the frame or the inside as space or personal choice dictates Outside the Frame Inside the Frame Figure 9 Figure 10 AirDog FP 100 amp FP 150 Ford PowerStroke 2003 2007 6 0L Section 4 AirDog amp Mounting Brackets Installing the AirDog amp Mounting Brackets on the Truck s Frame cont d NOTE You may attach the AirDog to the bracket either before or after attaching the assembly to the frame whichever is easier Mount the AirDog so the FUEL IN port is directed toward the rear of the vehicle 4 3 Loose assemble the AirDog and brackets to the vehicle by clamping the Figure 13 4 4 Position the AirDog on the frame as necessary for clearance Properly torque the fasteners 10 AirDog FP 100 amp FP 150 Ford PowerStroke 2003 2007 6 0L Section 5 A Fuel Lines Fuel Supply Line from the AirDog to the High Pressure Pump 5A 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 depressi
19. nstallation 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 15 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 AirDog FP 100 amp FP 150 Ford PowerStroke 2003 2007 6 0L Section 3 Parts List PowerStroke Parts List Installation Manual ADI F 100 150 FP 100 1 AirDog Or 150 E AirDog Mounting Bracket 001 3C 0004 v Mounting Hardware Kit 901 61 010
20. stock and slightly modified PowerStroke Diesels The AirDog FP 150 is recommended for highly modified PowerStroke Diesels PureF low products are manufactured with a personal touch unsurpassed attention to detail and the most stringent quality control TYPICAL INSTALLATION LAYOUT Desh Plate Fuel Line Indicator Light T ust Retum To Tank P 4 y Fuel Tank Filler Tube Electric Fuel Line P To Engine High Pressure Fuel Pump Figure The AirDog draws fuel from the fuel tank at a constant flow removing water particulates and air vapor while maintaining a regulated pressurized fuel flow to the stock OE high pressure pump The separated air vapor 1s 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 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 blue tabs on the female connector wh
21. und fitting to prevent splatter Catch all spilled fuel and dispose of properly 7 4 Start engine RECHECK ALL FUEL FITTINGS FOR LEAKAGE AND PROPERLY TORQUE 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 Checking Pump Noise NOTE Each AirDog has been manufactured in a Quality Controlled process and wet tested for operation and performance before shipment This is a very quiet and smooth running system With fuel or air alone the AirDog fuel pump will run very quietly However if any fuel fitting on the vacuum side between the fuel tank and the AirDo or the water separator has been left loose during the installation process the system may suck air at an excessive rate and will be very noisy To check for this problem unscrew the water separator 3 or 4 full turns and activate the AirDog by turning the ignition switch to on If the AirDog runs quietly then excessive air from a loose fitting or leaking water separator seal is most likely the reason for the excessive noise Correct as necessary A The seal groove in the 3 filter 15 a snug fit and on occasion the seal has been found to not be fully seated Remove the water separator remove the seal from the top of the nut plate Clean and lubricate the seal grove Carefully replace the seal in the grove Be sure to fully seat the seal B Check all
22. y leads to the alternator instead of the battery will create a corrosion free connection Black Red 6 4 Route the power supply leads to the alternator Connect the Black lead to the alternator Ground connection Connect the Red lead to the alternator Hot Lead going to the battery Figure 66 OR 6 5 Should you choose to connect the power supply leads directly to the battery connect the RED lead to the POSITIVE post of the driver s side battery Connect the BLACK lead to the NEGATIVE post of the same battery Figure 67 6 6 Route the wiring harness to the AirDog and connect the 2 pin Deutsch connector to the corresponding connector on the AirDog Figure 68 19 AirDog FP 100 amp FP 150 Ford PowerStroke 2003 2007 6 0L Section 7 Initial Startup Procedures INITIAL START PROCEDURE The AirDog is a self priming system however to prevent potential damage and reduce the life expectancy of the system it is recommended to pre fill only the water separator with diesel fuel before initial startup 7 Pre fill the water separator with diesel fuel 7 2 Turn the starter key to the on run position 7 3 While the AirDog is operating bleed the fuel line to the engine of air by loosening the fuel line connection at the engine fitting As soon as the line is purged of air and pure fuel is observed properly tighten the fuel fitting NOTE put a rag or shop towel over and aro
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