INSTALLATION MANUAL

#28

FOR 24 VALVE 5.9L/6.7L CUMMINS

POWERED

DODGE TRUCKS

2005 THROUGH Present

PLEASE READ THESE INSTRUCTIONS THOROUGHLY

BEFORE BEGINNING INSTALLATION!

With New Quick Connect Components!

MODEL RP-100 & RP-150

Performance Fuel System Parts

Wire Screen

Insert In Fuel Inlet

To Protect the Gerotor

Fuel Inlet

NOW

On Left Side

Adjustable

Regulator

OVERVIEW

Welcome to the

Raptor™ Fuel Pump!

The Raptor™ Fuel Pump is a Premium replacement lift pump for the Dodge Cummins 24 Valve

5.9L/6.7L diesel engine. A complete installation kit is included.

The output pressure for the 5.9L/6.7L 24 Valve Cummins engine is factory set at 15/18 PSI.

Pressure and flows are approximate as they will vary with fuel temperature and as the brushes wear in, also from variations of vehicle voltage/amp output and fuel line installation.

The RP-100 is recommended for stock and slightly modified 5.9L/6.7L Cummins Diesels.

The RP-150 is recommended for highly modified 5.9L/6.7L Cummins Diesels.

The Raptor™, a gerotor fuel pump, features an adjustable pressure regulator and has a protective wire screen insert at the fuel inlet.

PureFlow AirDog Products are Manufactured with a Personal

Touch,

Unsurpassed Attention to Detail

And

The Most Stringent Quality Assurance!

TYPICAL DODGE CUMMINS INSTALLATION LAYOUT!

Figure 1

NOTE: The pictures used in this manual are for example only and may not picture components exactly the same as found on your truck.

QUICK CONNECT COMPONENT OVERVIEW

Provided in this kit is an OE style quick connection system. This system allows 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 while you firmly pull the assembly apart.

Raptor™ 100 & 150

2005

– Present Dodge Cummins

Section 2 Safety Guidelines

Raptor™

MODEL RP-100 & RP-150

The installation of the Raptor™ Fuel Pump can be made relatively easy by following the steps outlined in this manual.

1. Inventory the package components completely. Notify PUREFLOW AIRDOG. immediately of any parts missing or damaged.

2. Read the installation manual and understand how the system operates 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.

NOTE: Some of the pictures used in this manual are for example only and may not picture a component exactly the same as found in your truck.

SAFETY GUIDELINES!

CAUTION:

Proper location of the Raptor™ on the vehicle is essential. Consider hazards presented to the equipment by road debris and the elements.

CAUTION:

CAUTION:

Chock the vehicle’s tires to prevent rolling.

CAUTION:

CAUTION:

Disconnect the battery cables to both batteries before proceeding with the

Raptor™ Fuel Pump installation.

Vehicle frame rails should not be drilled into or welded upon.

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 Raptor™!

QTY DESCRIPTION

1

INSTALLATION MANUAL

1

RAPTOR™ FUEL PUMP

1

Raptor™ 100 & 150

2005

– Present Dodge Cummins

Section 3 Parts List

Parts List

WIRING HARNESS

1 Set MOUNTING BRACKETS

1

Mounting Hardware Kit

1

Cable Ties

1

Spacer

Part Number

205-1-0111

RP-100 or

RP-150

5E-2-012

010-3C-0002PC

010-3C-0001PC

901-61-0102-PM-RP

5H-2-1-06/12

010-3C-0003-A-P

IMAGE

1

Suction Hose Assembly

WAP110-8-8

1

Pressure Hose Assembly

WAP110-8-8-90

1

Customer Service Oring Replacement Kit

2

Push Lock Hose Splice

901-05-0100

001-4A-1-0026

1/2” Male QC x 3/4-16 ORB

2

08J2044-3/4UNF

1

12mm X ½” Male SAE J2044 Quick

Connect Fitting

1

Sealing Washer (installs on WAP102 fitting)

1

Fuel Module Up Grade Kit

WAP 102

1P-5-DS

901-01-0510

1

Male Spade Connector

5D-1-08-A-16/14

ILLUSTRATION OF QUICK CONNECT COMPONENTS

Raptor™ 100 & 150

2005

– Present Dodge Cummins

Section 4 Raptor™ Fuel Pump & Mounting Brackets

Section 4: 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 1/2” O-ring Boss X 3/4” male fitting (08J2044-3/4UNF) into the Raptor™ port marked “IN”.

FUEL “IN” PORT FUEL “OUT” PORT

Figure 2

4-2. Install 1/2” O-ring Boss X 3/4” male fitting (08J2044-3/4UNF) into the port marked

“OUT”. Properly torque the fitting.

NOTE: The kitting provided is intended for inside frame rail mounting. Mounting inside the frame (Fig. 4) will give more protection from road debris.

Figure 3 Figure 4

4-3.

Assemble 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 (Fig. 4). Adjust the

Raptor™ up or down on the mounting bracket to clear fuel lines or wiring on the frame.

Use the spacer block to clear lines and wiring harnesses on the frame.

4-4. Loose assemble the mounting bracket and pump assembly to the frame with the backing plate using the 4 ½” x 3/8” bolts, lock washers, and nuts. After satisfactorily positioning the bracket and pump assembly, properly torque the fasteners.

Figure 5

Figure 6

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 Raptor™ mounting bracket, you may remove it! Be very careful not to damage the frame.

Raptor™ 100 & 150

2005

– Present Dodge Cummins

Section 5 Fuel Lines

Section 5A: Connecting the Raptor™ to the Filter Canister.

5A-1. Remove the original Banjo Bolt and fuel supply line from the factory fuel filter canister.

Figure 7 Figure 8

5A-2. Install the 12mm X ½” Male SAE J2044 Quick Connect Fitting with seal washer supplied into the inlet port on the fuel filter canister. Properly torque the fitting. Do not over tighten. The fitting could crack or break!

5A-3. Insert the female quick connect end (see figure 9) of the

“Pressure Hose Assembly” into the male quick connect fitting previously installed in the port marked “OUT”. You will hear a

“click” when it connects.

Figure 9

5A-4. Connect the other end of the “Pressure Hose Assembly” (Figure 10) to the inlet fitting installed in step 5A-2. It will “click” when properly connected.

Figure 10

5A-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.

Raptor™ 100 & 150

2005

– Present Dodge Cummins

Section 5B Fuel Lines

Fuel Suction Line for the Raptor.

5B-1. Insert the quick connect end (see figure 11) of the “Suction Hose

Assembly” to the male fitting install in the fuel “IN” port during step 4-1 of this manual. A “click” will be heard when the fitting is properly connected. female

Figure 11

5B-2.

Refer to the installation instructions within the Fuel Module Upgrade Kit. Install the

Fuel Module Upgrade Kit.

5B-3. Attach the female quick connect end of the “Suction Hose Assembly” to the bulk head male quick connect installed during the fuel module upgrade. (see Fig 12). A “click” will be heard when the fitting is properly connected.

Figure 12

NOTE: Figure 22 is for visual reference only. The fuel module in your vehicle may appear different.

.

5B-4 Any excess fuel hose can be addressed by routing the house 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.

Raptor™ 100 & 150

2005

– Present Dodge Cummins

Section 6 Electrical Harness

WIRING DIAGRAM

Figure 13

Installing the Raptor™ Fuel Pump wiring harness.

6-1. Connect the Power Supply Lead to the Raptor™, by inserting the 2 pin Deutsch connector on the end of the wiring harness into the corresponding connector on the

Raptor™.

Figure 14

6-2. Crimp the male spade connector on the end of the Red (+) wire.

Ground Wire

Hot Lead

Water Proof Fuse

Raptor Pump Lead

Figure 15 Figure 16

6-3. To connect to the power lead to the fuse panel, route the Red (+) wire to the fuse panel located under the hood on the driver’s side wheel house and insert the male spade connector into a spare fuse holder on the panel that is “hot” when the starter key is turned to the on position.

6-4. Connect the Green (-) wire to an adequate ground.

BE SURE TO PROPERLY ROUTE AND SECURE THE WIRING HARNESS TO THE

VEHICLE.

Raptor

™ 100 & 150

2005

– Present Dodge Cummins

Section 7 Final 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 and pumping fuel, bleed the fuel line to the filter head by loosening the fuel line connection at the filter head. As 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 adjustment screw. Then, 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. Should the base nut become loose, re-torque it immediately. When finished, properly torque the regulator adjustment screw lock nut!

Properly tighten the adjustment screw

Lock Nut

when finished.

Figure 49

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.