INSTALLATION MANUAL MODEL RP-100

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1 INSTALLATION MANUAL FOR 12 VALVE 5.9L CUMMINS POWERED DODGE TRUCKS 1994 THROUGH 1998 MODEL RP-100 READ THESE INSTRUCTIONS THOROUGHLY BEFORE BEGINNING INSTALLATION 5400 BUSINESS 50 WEST SUITE VOICE JEFFERSON CITY, MO FAX

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3 OVERVIEW Welcome to the Raptor Fuel Pump The Raptor RP-100 is a Premium replacement lift pump for the Dodge Cummins 12 Valve 5.9L diesel engine. A complete installation kit is included. The Raptor RP-100 maximum flow is 100 GPH. The factory set output pressure is at 25/30 PSI for the 5.9L 12 Valve diesel engine. The RP-100 is recommended for stock and slightly modified 5.9L Cummins Diesels up to 550+ HP. The Raptor, a gearotor fuel pump, features an adjustable pressure regulator and is also available as the RP-150. The Raptor RP-150 is recommended for highly modified 5.9L Cummins Diesels up to 1,200+ HP. PureFlow products are manufactured with a personal touch, unsurpassed attention to detail and the most stringent quality control! 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 TECHNOLOGIES, INC. Immediately of any parts missing or damaged. 2. Read the owner s manual and 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. Use good judgment and common sense when installing the Raptor Fuel Pump 5. Uncertain about any installation procedures? Contact PUREFLOW TECHNOLOGIES, INC for technical assistance. Please fill out and return the enclosed Product Registration/Warranty Card to PureFlow Technologies to register your warranty. 3

4 Section 1 Table of Contents TABLE OF CONTENTS Section 1....Table of Contents Section 2....Safety Guidelines Section 3...Parts List INSTALLATION PROCEDURES Section Raptor & Mounting Brackets Fuel Lines Section 5 A. The Mechanical Lift Pump Section 5 B...Raptor To Filter Canister Section 5 C..... Fuel Tank To Raptor Electrical Harness Section 6... Electrical Harness Section Final Check List 4

5 Section 2 Safety Guidelines SAFETY GUIDELINES! NOTE: WARNING! WARNING IMPORTANT CAUTION: CAUTION: CAUTION: Proper location of the Raptor on the vehicle is essential. Consider hazards presented to the equipment by road debris and the elements. Please be sure to chock the vehicle s tires to prevent rolling. Disconnect the battery cables to both batteries before proceeding with the Raptor Fuel Pump installation. Use diesel fuel compatible thread sealer on all NPT tapered pipe thread fuel fitting connections! 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. 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. TYPICAL RAPTOR INSTALLATION LAYOUT Figure 1 5

6 Section 3 Parts List Raptor 100 Parts List QTY DESCRIPTION IMAGE 1 INSTALLATION MANUAL 1 RAPTOR FUEL PUMP 1 WIRING HARNESS 1 MOUNTING BRACKETS 1 SPACER BLOCK 1 Set MOUNTING FASTENERS (3) 3/8-16 X 4 ½ Lg. HHCS (3) 3/8 Flat Washer (3) 3/8 Split Lock Washer (3) 3/8-18 Nuts (4) 5/16-18 X ¾ Lg. FH SHCS (4) 5/16 18 X 2 ¾ Lg. FH SHCS (If Spacer Block is used) 1 INLET FITTING -8JIC Male to ½ ORB 1 OUTLET FITTING -8 JIC Male to 3/8 NPT 2-8 JIC Swivel x 1/2 Push Lock 90 degree Fitting 1 FUEL LINE ½ 3-8 JIC SWIVEL TO ½ BARB 1 3/8 QUICK CONNECT 1 ¼ FEMALE NPT TO ½ BARB 1-8 JIC to 12mm Male with Seal Washer 1 BUNDLE OF CABLE TIES 6

7 Section 4 Raptor Fuel Pump & Mounting Brackets Mounting the Bracket and Raptor Pump to the Truck s Frame NOTE: The Raptor can be mounted on either the inside or the outside of the frame. Mounting inside the frame will give more protection from road debris Assemble the Raptor to the mounting bracket as shown in Figure 2. Hold the assembly next to selected location on the frame to check for clearance. Adjust the Raptor up or down on the mounting bracket as necessary. To clear fuel lines or wiring on the frame, use the spacer block as necessary Loose assemble the mounting bracket, with pump attached, to the frame with the backing plate using 3/8 x 4 ½ bolts, lock washers, and nuts included in the kit. After positioning the bracket and pump assembly, properly torque the fasteners. Figure 2 Typical Mounting Location of Raptor Pump Location may vary due to particular truck model and year. The Raptor Fuel Pump must be mounted with the electric motor up, as shown! Figure 3 Step Install the 3/8 NPT x -8 Flare Fitting into the port marked OUT. Use diesel compatible thread sealer when installing this fitting. Properly torque the fitting. 7 Step 4-4 Install the Boss o-ring X -8 SAE fuel fitting into the Raptor port marked IN. Verify the wire screen insert is in place before installing the fitting. Properly torque the fitting.

8 Section 5 Fuel Lines The Factory Mechanical Lift Pump Must Be Disabled! 5A-1. Remove the factory lift pump by removing the bolts securing it to the engine. 5A-2 Remove the plunger from the rear of the pump. 5A-3 Reinstall the mechanical pump. Section 5B: Connecting the Raptor to the Filter Canister. 5B-1. Remove the Banjo fuel line fitting and fuel supply line from the original factory fuel filter canister. Filter Canister Fuel In Fitting Figure 4 5B-2. Install the 12mm x -8 flare fitting with O-ring supplied into the inlet port on the fuel filter canister. Properly torque the fitting. 5B-3 Measure and cut the length of fuel line required to connect the Raptor fuel Out fitting (Ref. Fig. 5) to the filter canister inlet port (Ref. Fig. 4). Connecting the Raptor fuel outlet to the filter canister inlet. Fuel OUT Figure 5A 8 Figure 5B Fuel In Fitting The Raptor can be mounted either outside (Fig. 5A) or inside the frame (Fig. 5B).

9 Section 5 Fuel Lines Connecting the Raptor to the Filter Canister, cont d Lubricate the hose barb with oil. Push the fuel line completely on the hose barb. 5B-4. Install a -8 Swivel x 1/2" Push Lock fitting on each end of the new fuel line. 5B-5. Connect one end of the new line to the Raptor OUT port. 5B-6. Carefully route the fuel line to the filter canister. Connect the -8 swivel to the In port fitting on the filter canister. (Ref. Fig. 4). Properly torque the fitting. Section 5C: Connecting the Raptor to the Fuel Tank. 5C-1 Remove the original fuel suction line from fuel tank by squeezing the tabs on the end of the connector together. Figure 6 Figure 7 (In more detail) To release the original fuel supply line from the fuel tank suction tube, center and firmly push the factory Quick Connect fitting against the suction tube. While firmly holding the plastic retainer ring onto the fitting, depress and hold the plastic ring. Now, pull the quick release fitting from the suction tube. It can be difficult to disconnect the fitting if the retainer is cocked and not held perfectly square to the tank suction tube. Important: After removing the factory line check to make sure that the plastic retainer was removed from the suction tube with the line. If the retainer remains attached to the tank suction tube, the new Raptor fuel supply line Quick Connect will not properly seat. Consult the factory manual if unsure of this procedure! 9

10 Section 5 Fuel Lines Section 5C: Connecting the Raptor to the Fuel Tank, cont d. 5C-2 From the end of the fuel line supplied with the attached 'Quick Connect' fitting, measure and cut the length of line required to connect the fuel tank SUCTION port to the Raptor inlet port marked "In". Figure 8 Figure 9 5C-3 Assemble the -8 female swivel x 1/2" 'push lock' fitting into the opposite end of the fuel line from the Quick Connect fitting. Fuel Line - 8 Flare Fitting To fuel tank To Raptor fuel in port Figure 10 5C-4 Connect the new fuel line to the fuel tank by firmly pushing the quick connect fitting onto the suction tube. Be sure the connector seats, you should be able to hear or feel the quick connect click as it seats. Figure 11 Figure 12 5C-5 Connect the opposite end of the 'New Fuel Suction Line' to the -8 flare fitting at the Raptor fuel inlet port marked In. NOTE: The bed does not need to be removed to remove and connect the fuel line. This was done only to enable the taking of the instructional picture. 10

11 Section 6 Electrical Harness WIRING DIAGRAM NOTE: The relay wiring harness is not used on this Raptor installation. Figure13 Installing the Raptor Fuel Pump wiring harness 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 Crimp the female spade connector on the end of the Red (+) wire. Figure 15 Figure 16 Figure Route the Red (+) wire to the fuse panel located under the hood on the drivers side wheel house and insert it into a spare fuse holder on the panel that is hot (Ref. Fig. 15 & 16) when the starter key is turned to the on position. 6-4 Connect the Green (-) to an adequate ground. BE SURE TO PROPERLY ROUTE AND SECURE THE WIRING HARNESS TO THE VEHICLE. 11

12 Section 7 Final Check List INITIAL START PROCEDURE 7-1 Turn the starter key to the on/run position. Note: It may be necessary to momentarily engage the starter for the ECM to energize the Raptor Fuel Pump 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. 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 7-4 To adjust the fuel pressure, if necessary, first loosen the lock nut on the regulator body 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. Should the base nut become loose, re-torque it immediately. When finished, properly torque the regulator lock nut! Properly tighten the adjustment screw lock nut when finished. Figure 18 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. NOTE: Should any installation problems arise, please call toll free Monday Friday, 8:00 am 5:00 pm CST, for assistance. 12

13 NOTES 13

14 NOTES 14

15 Copyright 2008 PFT Bulletin No. RPI PureFlow Technologies, Inc. Printed 08 All Right Reserved Revised February 10,

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