INSTALLATION MANUAL MODEL RP-100

INSTALLATION MANUAL FOR 24 VALVE 5.9L CUMMINS POWERED DODGE TRUCKS 2003 THROUGH 2004.5 MODEL RP-100 READ THESE INSTRUCTIONS THOROUGHLY BEFORE BEGINNING INSTALLATION 5400 BUSINESS 50 WEST SUITE 8 573 635-0555 VOICE JEFFERSON CITY, MO 65109 573 635-0778 FAX www.pureflowtechnologies.com

"Many thanks to Richard and Glacier Diesel Power for the photographs contributed for use in this manual!" 2

OVERVIEW Welcome to the Raptor Fuel Pump The Raptor RP-100 is a Premium replacement lift pump for the Dodge Cummins 24 Valve 5.9L diesel engine. A complete installation kit is included. The Raptor RP-100 flows 100 GPH and 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

Section 1 Table of Contents TABLE OF CONTENTS Section 1....Table of Contents Section 2....Safety Guidelines Section 3...Parts List INSTALLATION PROCEDURES Section 4.. Raptor & Mounting Brackets Fuel Lines Section 5 A....Raptor To Filter Canister Section 5 B.... Fuel Tank To Raptor Electrical Harness Section 6....Electrical Harness Section 7.......Final Check List 4

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

Section 3 Parts List Raptor 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 1 FUEL LINE ½ 3-8 JIC SWIVEL TO ½ BARB 1 3/8 QUICK CONNECT 1 ¼ FEMALE NPT TO ½ BARB 1 BUNDLE OF CABLE TIES 1 FUEL FITTING (For Filter Canister Inlet) 6

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. 4-1. Assemble the Raptor to the mounting bracket as shown (Fig. 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. 4-2. 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, properly torque the fasteners. Figure 2 Typical Mounting Location of Raptor Pump Location may vary due to particular truck model and year. Figure 3 Step 4-3.. 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. 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. 7

Section 5 Fuel Lines Section 5A: Connecting the Raptor to the Filter Canister. 5A-1. Remove the Lift Pump and fuel supply line from the original factory fuel filter canister. Fuel Filter Canister Figure 4-A Figure 4-B 5A-2. Install the 2 hole mounting plate x -8 flare fitting with O-ring into the inlet port on the fuel filter canister with the original pump mounting screws. Properly torque the fitting. 5A-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-A & B). Connecting the Raptor fuel outlet to the filter canister inlet. Fuel OUT The direction of the fuel lines reflect an outside the frame mounting location. The Raptor Fuel Pump can be mounted inside or outside the frame. Figure 5

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. 5A-4. Install a -8 Swivel x 1/2" Push Lock fitting on each end of the new fuel line. 5A-5. Connect one end of the new line to the Raptor OUT port (Ref. Fig. 5). 5A-6. Carefully route the fuel line to the filter canister. Connect the -8 swivel to the In port fitting on the filter canister. (Ref. Figs. 4A & B). Properly torque the fitting. Section 5B: Connecting the Raptor to the Fuel Tank. 5B-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 blue plastic retainer was removed from the suction tube with the line. If the blue 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

Section 5 Fuel Lines Section 5B: Connecting the Raptor to the Fuel Tank, cont d. 5B-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 5B-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 5B-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 5B-5 Connect the opposite end of the 'New Fuel Suction Line' to the -8 flare fitting at the Raptor fuel inlet port marked In. 10

Section 6 Electrical Harness The Raptor Fuel Pump is equipped with a relay controlled wiring harness that is activated through the OE fuel pump connection! Figure 13 Securing the Relay and Fuse Holder to the Vehicle 6-1. Secure the relay and fuse holder to the vehicle on the firewall near the steering column or a more suitable location, if appropriate. Figure 14 Figure 15 Connecting to the ECM Lead 6-2. Disconnect the OE fuel pump lead from the ECM connection (Deutsch, two pin connector). Carefully route and connect the Raptor relay lead (Deutsch, two pin Connector) to the ECM pump lead. Figure 16 Figure 17 6-3. Route the wiring harness pump lead to the Raptor. Connect the Deutsch connector on the Raptor to the corresponding lead on the wiring harness. 11

Section 6 Electrical Harness Connecting the power supply leads to the alternator instead of the battery will create a corrosion free connection. Green (-) Red (+) Replace the Protective Cover Figure 18 Figure 19 6-2. Route the Red & Green power supply lead to the alternator Connect the Green (-) lead to the alternator Chassis Ground connection. Connect the Red (+) lead to the alternator Hot Lead battery connection. Connecting the power supply leads to the battery. 6-3 Connect the RED (+) lead to the POSITIVE (+) post of the driver's side battery. Connect the GREEN (-) lead to the NEGATIVE (-) post of the same battery. Green (-) Red (+) Figure 20 Connecting the Power Lead to the Raptor 6-4. Route the wiring harness to the Raptor. Connect the 2 pin Deutsch connector to the corresponding connector on the Raptor Figure 21 BE SURE TO PROPERLY ROUTE AND SECURE THE WIRING HARNESS TO THE VEHICLE. 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 clock wise to increase pressure or counter clockwise to decrease pressure. Be careful not to loosen the regulator assembly base. When finished, properly torque the regulator adjustment screw! Properly tighten the adjustment lock nut when finished. Figure 22 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 1-877-463-4373, for assistance, Monday Friday, 8:00 am 5:00 pm CST. 13

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