INSTALLATION MANUAL MODEL RP-100 & RP-150

Transcription

1 INSTALLATION MANUAL FOR DURAMAX DIESEL POWERED PICKUP TRUCKS MODEL RP-100 & RP-150 READ THESE INSTRUCTIONS THOROUGHLY BEFORE BEGINNING INSTALLATION 5400 BUSINESS 50 WEST SUITE VOICE JEFFERSON CITY, MO FAX

2 Adjustable Regulator Wire Screen Insert 2

3 OVERVIEW Welcome to the Raptor Fuel Pump The Raptor Fuel Pump is a Premium Performance lift pump for the DuraMax Diesel engine. A complete installation kit is included. The maximum flow of the RP-100 is 100 GPH and the RP-150 is 150 GPH. The output pressure for the DuraMax Diesel engine is factory set at 15/18 PSI. The RP-100 is recommended for stock and slightly modified DuraMax up to 550+ HP. The Raptor RP-150 is recommended for highly modified up to 1,200+ HP. The Raptor, a gearotor fuel pump, features an adjustable pressure regulator and has a protective wire screen insert at the fuel inlet. 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 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 Within Thirty Days of Purchase to register your warranty. 3

4 Raptor 100 & 150 Section 1 Table of Contents TABLE OF CONTENTS Section 1....Table of Contents Section Safety Guidelines Section 3....Parts List INSTALLATION PROCEDURES Section 4... Raptor & Mounting Brackets Fuel Lines Section 5 A..Removing the Fuel Supply Line Section 5 B.Raptor to Engine Supply Line Section 5 C.....Raptor to Fuel Tank Electrical Harness Section Electrical Harness Section Final Check List 4

5 Raptor 100 & 150 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 DURAMAX RAPTOR INSTALLATION LAYOUT! Figure 1 5

6 Raptor 100 & 150 Section 3 Parts List DuraMax Raptor Installation Parts List QTY DESCRIPTION IMAGE 1 INSTALLATION MANUAL 1 RAPTOR FUEL PUMP 1 WIRING HARNESS 1 Spade Connector 1 MOUNTING BRACKETS 1 SPACER BLOCK ( As needed to clear cables) 1 Set MOUNTING FASTENERS 3 ea 4 ½ Lg. HHCS 3 ea Split Lock Washer 3 ea Nuts 4 ea 5/16 X ¾ Lg. FH SHCS 4 ea 5/16 X 2 ¾ Lg. FH SHCS (If Spacer Block is used) 1 FUEL LINE ½ x 15 Feet 1 INLET FITTING -8JIC Male to ½ ORB 1 OUTLET FITTING -8 JIC Male to 3/8 NPT 2-8 Swivel x ½ Push Lock 2 Dorman 1/2 Quick Connect 2 3/8 NPT x ½ Push Lock (Attaches to Dorman Quick Connect) 1 BUNDLE OF CABLE TIES 6

7 Raptor 100 & 150 Section 4 Pump & Mounting Bracket Section 4: Mounting the Raptor to the Truck s Frame! The Raptor Fuel Pump must be mounted with the electric motor up, as shown! Step 4-1. 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. Figure 2 Step 4-2. 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. NOTE: The Raptor can be mounted on either the inside or the outside of the frame. Mounting inside the frame (Fig. 3C) will give more protection from road debris. Figure 3A Figure 3B Figure 3C 4-3. Assemble the Raptor to the mounting bracket as shown in Fig. 3A. Hold the assembly next to the selected location on the frame to check for clearance (Fig. 3B). To clear fuel lines or wiring on the frame, adjust the Raptor up or down on the mounting bracket as necessary (Fig. 3C). Use the spacer block, if needed 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 positioning the bracket and pump assembly at the selected location, properly torque the fasteners. 7

8 Raptor 100 & 150 Section 5 Fuel Lines Section 5A: Removing the Original Fuel Supply Line! 5A-1. To access and remove the fuel supply line from the suction tube on the top of the fuel tank, it may be necessary to pull down on the sheet metal shield from the driveshaft side. 5A-2. Slide the 1/2 fuel line disconnect tool under the fuel line connection and disconnect the quick connect fitting. Remove the fuel line from the tank. Suction Tube Supply Line to Engine Figure 4 Figure 5 5A-3. Remove the end of the fuel supply line from the frame mounted line to the engine. This is the connection located between the fuel cooler and the front of the fuel tank. Slide the fuel line disconnect tool under the fitting as in step 2 and disconnect the line. You can now remove the factory fuel line from the vehicle. SECTION 5B: Connecting the Raptor to the Engine Supply Line! 5B-1. Measure and cut the length of line required, when properly routed, to connect the Raptor fuel to engine port marked OUT to the engine supply line. Cut the fuel line an adequate length to ensure a smooth radius at the bends. Figure 6 5B-2. Assemble the 3/8 NPT Push Lock fitting to the Dorman Quick Connect fitting. Then, pushing firmly, fully seat the push lock fitting into the fuel line.

9 Raptor 100 & 150 Section 5 Fuel Lines Section 5B: Connecting the Raptor to the Engine Supply Line, cont d! Lubricate the barb end of the Push Lock fitting with oil. Push the fuel line completely onto the barb end of the fitting. Figure 7A Figure 7B 5B-3. Insert the -8 swivel x ½ 90 o push lock fitting into the opposite end of the same fuel line. Pushing firmly, fully seat the push lock fitting into the fuel line. Figure 8 Figure 9 5B-4. Connect the -8 swivel to the fitting in the port marked OUT. (Fig. 8) Properly torque the fitting. 5B-5. Connect the Quick Connect to the fuel line leading to the engine. Push firmly until it clicks, locking it into place. SECTION 5C: Connecting the Raptor to the Fuel Tank Suction Line! Figure 10 9 Figure 11 5C-1. Measure and cut the length of line required, when properly routed, to connect the fuel tank suction tube to the Raptor fuel inlet port, marked IN. 5C-2. Assemble the 3/8 NPT Push Lock fitting to the Dorman Quick Connect fitting. Insert the push lock end of the fitting assembly into the end of the ½ fuel line (Ref. Fig. 6). 5C-3. Insert the push lock end of the -8 swivel x ½ 90 o push lock fitting (Ref. Fig. 7A&B) into the opposite end of the same fuel line Pushing firmly, seat the push lock fittings fully into the fuel line.

10 Raptor 100 & 150 Section 5 Fuel Lines SECTION 5C: Connecting the Raptor to the Fuel Tank Suction Line, cont d! Figure 12 Figure 13 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. 5B-5. Connect the -8 swivel x ½ 90 o push lock fitting on the new fuel suction line to -8 male flare fitting on the Raptor fuel inlet port marked 'IN'. NOTE: BE SURE TO PROPERLY ROUTE AND SECURE THE FUEL LINES TO THE VEHICLE. 10

11 Raptor 100 & 150 Section 6 Electrical Harness DURAMAX RAPTOR WIRING DIAGRAM Figure 14 Installing the Raptor Fuel Pump wiring harness. Figure 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 6-2. Route the wiring harness from the Raptor to the fuse/relay panel located under the hood on the drivers side wheel house Crimp the female spade connector on the end of the Red (+) wire. Ground Wire Hot Lead Water Proof Fuse Raptor Pump Lead Figure 16 Figure 17 Figure Route the Red (+) wire to the fuse panel located under the hood on the driver s side wheel house and insert it into a spare fuse holder on the panel that is hot when the starter key is turned to the on position (Ref. Fig. 17 & 18). Secure the wire with plastic ties Connect the Green (-) to an adequate ground. BE SURE TO PROPERLY ROUTE AND SECURE THE WIRING HARNESS TO THE VEHICLE. 11

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13 Raptor RP-100 & 150 Section 7 INITIAL START PROCEDURE 7-1. Turn the starter key to the on/run position. Final Check List 7-2. While the Raptor Fuel Pump is on, bleed the fuel line by loosening the fuel line OUT connection. 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 Start engine!. 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 19 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. 13

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16 Copyright 2008 PFT Bulletin No. RPI DM-100 PureFlow Technologies, Inc. Printed 08 All Right Reserved Revised March 9,