FIG. 3 BRACKET INSTALLATION. i a. e h f FIG. 4 STATOR OFFSET BRACKET REMOVE OEM SPACER. REPLACE WITH BRACKET 3.

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2 IG. 3 BRACKET INSTALLATION E D 11 C B i a b c d e h f g A B C A IG. 4 STATOR OSET BRACKET 14 G REMOVE OEM SPACER. REPLACE WITH BRACKET 3. 9 G

3 DewEze Clutch Pump Kit ord 6.7L, AA Pump, 2011 INSTALLATION INSTRUCTIONS 1. The installation of this kit requires trained decisionmaking concerning clearances, tying components together, rerouting, or relocating OEM components, etc. It is impossible to describe all of the clearance and vibration points, etc. in the installation instructions. Therefore, the technician must exercise professional judgment to achieve the best quality installation. 2. Disconnect the battery. 3. Open all clips to the air cleaner lid and loosen clamp on the air inlet of engine. Remove the entire air intake tube and air cleaner lid as an assembly. 4. Loosen engine belt and slide belt off of the upper idler pulleys and move aside; DO NOT REMOVE THE OEM BELT ROM THE TRUCK. Remove both OEM idler pulleys from the truck at locations D and. Reinstall one idler and bolt at location E. 5. Remove bolts at locations A, B and C. Remove the Stator bushing shown in ig. 4. There is a 13mm nut on the front side of the stator tab. To remove the OEM spacer it will be helpful to also remove the nut on the stator spacer on the upper driver side of engine to allow the stator to move forward slightly. 6. Insert stator bushing (2) into large hole in rear of stator at Location G. Insert the stator offset clip (3) between points and G. Thread M8 x 20 flange head bolt (8) through rear hole of clip into engine at Location. Insert M8 x 25 button socket head bolt (9) into front hole of clip, through stator with bushing (2), and thread M8 flange nut (4) onto bolt. 7. Install fittings into pump (10). See ig. 5. Suction fitting points down and to the front at a 45 angle. The pressure fitting points straight up. Hold pump (10) onto back of bracket (1) and clutch hub (11i) onto front of bracket. Place two 3/8 x 1 1/4 socket head bolts (16) and 3/8 high collar lock washers (17) through pump, through mounting plate and thread into hub. Torque to 20 lb-ft. INSTRUCTION SHEET OR THE CLUTCH OR CORRECT INSTALLATION O SNAP RINGS. 9. Slide clutch pulley (11c) onto hub. Install small snap ring (11d) to hold pulley in place. 10. Place the key onto the pump shaft. Slide the hub/armature (11f) onto the pump shaft aligning the keyways. NOTE: SET THE AIR GAP BETWEEN THE HUB/ARMATURE AND THE PULLEY USING SHIMS (11e) ACCORDING TO INSTRUCTION SHEET OR CLUTCH. 11. Thread bolt (11g) and lock washer (11h) into pump shaft. Torque to value in clutch instruction sheet. 12. Install bracket (1) with pump onto the truck using M8 x 120 socket head bolt (6) at location A, M8 x 130 hex head bolt (5) at Location B and M8 x 140 hex head bolt (7) at location C as shown in ig Reinstall the OEM belt with the new routing shown in ig Place the hose insulation sheaths where the hoses run close to the EGR assembly to protect the hoses from the heat. Slip the small hose insulation sheath (19) over the pressure hose. Slip the large hose insulation sheath (18) over the suction hose all the way up to the pump fitting. asten the sheaths to the hoses with the nylon cable ties (20). Make all hose connections to the pump. 15. Reinstall the intake air tube and air cleaner lid as removed. 16. Reconnect the battery. 17. Run the engine and check for any clearance or alignment problems. Adjust as needed. 8. Slide coil (11a) over hub. Install large snap ring (11b) to hold coil in place. NOTE: THE BEVEL ON BOTH SNAP RINGS MUST ACE AWAY ROM THE PUMP. REER TO 1

4 INSTALLATION INSTRUCTIONS AA PUMP WITH WARNER HUB-CLUTCH 1) HUB CLUTCH ASSEMBLY a) ield coil b) ield coil snap ring c) Pulley d) Pulley snap ring e) Shims f) Armature g) Shaft bolt h) Lock washer i) Hub j) Anti-rotation pin 2) Pump (AA-mount) 3) Key (attached) 4) Bolt kit PROCEDURE Warning: ailure to install snap rings per these instructions can be verified and will void the clutch warranty. Step 1: Preparation of field coil (1a) a. Align the hole in the back plate of the field coil with the anti-rotation pin (1j) in the hub (1i). Place the field coil into position. b. With a snap ring pliers, spread the field coil snap ring (1b) and insert it into the groove on the hub nose. c. Verify that the snap ring is fully seated in the groove around its circumference to assure assembly retention. USE THE CORRECT SNAP RING: ield coil snap ring (1b) largest Pulley snap ring (1d) smallest To assure assembly retention, the ring bevel must face away from the pump. See figure below. Cross-section of snap ring PUMP Bevel Snap ring CORRECT POSITION Step 2: Preparation of pump (2) a. Clean pump shaft of all dirt, grease or debris. b. Check mounting surface for nicks, burrs or scratches. Smooth with a file or emery cloth, if necessary. Snap ring INCORRECT POSITION Harper Industries, Inc. 151 E. Hwy. 160 Harper, KS Tel ax Website: info@deweze.com

5 Step 3: Installation of clutch (1) a. Position pump and hub with field coil on both sides of bracket and secure with bolts from bolt kit (4). b. Connect one wire to the engine as a ground and the other to the hot wire coming from the switch. Rotate field coil COUNTER-CLOCKWISE to remove slack from wires. Be sure that wires are not pinched or rubbing. c. Slide pulley (1c) onto the pump shaft until it butts against the field coil. If the pulley does not slide on easily, check the mounting surface on the hub nose for nicks or burrs and remove them. d. With a snap ring pliers, spread the pulley snap ring (1d) and insert it into the groove on the hub nose. e. Verify that the snap ring is fully seated in the groove around its circumference. To assure assembly retention, the ring bevel must face away from the pump. Step 4: Installation of armature (1f) a. Align the armature keyway with pump shaft key (3) and slide the armature onto the shaft. b. Set the pulley to armature air gap at to inches by adding or removing shims (1e). Measure using a feeler gauge at three locations 120 apart. c. Install the lock washer (1h) and shaft bolt (1g). Torque bolt to inch-pounds. Step 5: Clutch assembly check a. Rotate clutch and check for rubbing or interference. b. The shims (1e) may compress when the shaft bolt is tightened; therefore, re-check the air gap at three locations 120 apart. c. Cycle clutch using the switch inside the vehicle or electrical damage may result. d. Burnish clutch as follows: Run the engine at 1250 RPM, and cycle the clutch ON and O 10 to 12 times over one minute. TROUBLESHOOTING: SYMPTOM CAUSE CORRECTION Clutch will not disengage. Clutch will not engage. Clutch is noisy. Clutch slips. Improper pulley to armature air gap (too small). Current is always on. Pulley snap ring not installed correctly. Improper pulley to armature air gap (too big). ield coil electrical wiring is not connected. aulty field coil. Less than 10.8 volts supplied to field coil (all accessories on). ield coil or pulley snap rings are not installed correctly. Belts too loose. Bearings noisy (new clutch only). Clutch not burnished. Belts too loose. Voltage to field coil less than 10.8 volts (all accessories on). Improper wiring or connections. Oil or grease on friction surfaces. Clutch not burnished. Reset air gap per instructions. Install per instructions. Reset air gap per instructions. Connect field coil wiring. Check field coil for continuity. Check for correct installation. Tighten or replace tensioner. Return to manufacturer. Burnish per instructions. Tighten or replace tensioner. Replace clutch. Burnish per instructions. Ref.: Warner Electric South Beloit, IL Harper Industries, Inc. 151 E. Hwy. 160 Harper, KS Tel ax Website: info@deweze.com