L DODGE CUMMINS BD FLOWMAX LIFT PUMP KIT

Transcription

1 6/15/2016 # D Dodge Cummins FlowMAX Lift Pump Kit (I-00329) L DODGE CUMMINS BD FLOWMAX LIFT PUMP KIT Installation Instructions P/N # D PLEASE READ ALL INSTRUCTIONS CAREFULLY BEFORE INSTALLATION. The BD auxiliary lift pump kit will provide the safety and performance of enhanced fuel flow to your Cummins engine. This pumps idle pressure will be psi, rather than psi.

2 6/15/2016 # D Dodge Cummins FlowMAX Lift Pump Kit (I-00329) Kit Contents: P FLOWMAX Lift Pump V3 M8 Flat Washer Self Threading 3/8 Bolt Flange M8 X 30mm Mounting Bracket Qty: 1 Qty: 3 Qty: 3 Qty: 3 Qty: Anti-Vibration Mount 3/8 Flat Washer Hose Clamp T-Bolt Clamp Qty: 3 Qty: 3 Qty: 6 Qty: FlowMAX Lift Pump Wiring Harness 3/8 Fuel Hose Qty: 1 Qty: 36

3 6/15/2016 # D Dodge Cummins FlowMAX Lift Pump Kit (I-00329) M Tie Wrap -AN 8 ORB x 3/8 Barb Filter Fitting Qty: 10 Qty: 1 Qty: Flowmax Bracket (box frame) Mount Strap 20.7 Qty: 1 Qty: 2 Optional Accessories: Low Fuel Pressure LED Alarm kit PFF Post filter with Filter Head Kit WSP Water Separator with Head Kit Required Tools: 5mm Allen wrench Drill 1/8 and 21/64 Drill bits Pliers 3/16 Flat Screwdriver Crescent Wrench Hammer 10 mm Socket or wrench Small Pipe Cutter Knife To Cut Fuel Hose 9/16 Socket or Wrench 7/16 Socket or Wrench Punch Installation: 1. Disconnect both batteries. 2. Raise the vehicle and support it safely.

4 6/15/2016 # D Dodge Cummins FlowMAX Lift Pump Kit (I-00329) Mounting Option 1 - Mounting Bracket using straps 3. Find a suitable place to mount the bracket to the inside of the frame; closest to the fuel tank. Avoid mounting where the bracket could rub on fuel lines, break lines and cables. Install straps around frame and bracket and torque to in/lbs. NOTE: The Nylock nut must be on the opposite side of the frame from the bracket. Inside of frame Align strap close to tabs Note orientation of bracket Straps & Frame Not shown Mounting bracket Isolator 4. Insert the three rubber isolators into the support bracket. Use some water to aid in lubricating the isolators as the slide into the bracket. Support Bracket Washer Bolts Place the large washers on the inside of the bracket against the rubber isolator. Tighten the supplied M8 bolts through each vibration isolator of the support bracket and into mounting bracket (PEM) nut. Repeat this step for the other 2 bolts. Torque the three bolts to 10-14ft-lbs.

5 6/15/2016 # D Dodge Cummins FlowMAX Lift Pump Kit (I-00329) Mounting Option 2 - Mounting the Pump Bracket to the Frame 3. From underneath the vehicle locate the cross member bracket on the inside of the driver s frame rail. Position and tape drill template (from the back of this manual) onto the frame rail just above the weld. Place fuel pump and bracket in place to ensure ample clearance. Mark holes with center punch. Remove drill template and drill pilot holes to 1/8. Drill main holes to 21/ Insert the three rubber isolators ( ) into the support bracket. Use some water to aid in lubricating the isolators as the slide into the bracket. Place the large washers ( ) on the inside of the bracket against the rubber isolator. Using a air ratchet (9/16 socket) tighten the self threading 3/8 bolt ( ) through each hole if the support bracket assembly and into the frame. Repeat this step for the other 2 bolts. Torque the three bolts to 25ft-lbs

6 6/15/2016 # D Dodge Cummins FlowMAX Lift Pump Kit (I-00329) Locate the two supplied T Bolt band clamps; unthread the nut (7/16 Socket) from each of them. Spread the clamps apart and insert them through boxed cutouts. With both clamps inserted, place the pump into place and align the inlet and outlet parallel to the frame. The inlet ( IN ) should be pointed towards the fuel tank. Tighten the clamps around the motor body, as seen in photo. Torque nuts to 80 in-lbs. Insert clamp through Insert clamp Fitting 6. Insert the Filter fitting ( M) into the (IN) side of the pump and the ORB fitting ( ) into the outlet of the pump. Do not over tighten as they use an o-ring for sealing. Refer to diagram in step 8 Fitting NOTE: If installing a filter kit, skip this step and refer to the Flomax Filter Kit manual for the install procedure for the water separator and fuel filter. Once Filter install is complete; continue to step 7.

7 6/15/2016 # D Dodge Cummins FlowMAX Lift Pump Kit (I-00329) With the pump mounted, cut the hard fuel line about 12 from the outlet side of the pump, on the inside of the frame rail. The fuel supply line is the thickest of all three lines. A tube cutter does not need to be used for this cut. 8. Using a flaring tool or punch, create a small flare on the cut hardline. If a flaring tool is not available, double clamp the fuel hose on the hardline side only. OUTLET 9. Cut the fuel supply line at the front of the fuel tank. Connect the cut portion of the fuel line to the inlet fitting on the Flomax pump using the supplied 3/8 fuel hose. Tighten the connections with the supplied hose clamps.

8 6/15/2016 # D Dodge Cummins FlowMAX Lift Pump Kit (I-00329) You will now need to drop the factory fuel tank. Be very careful as a full fuel tank is heavy. a. Use a transmission jack or something of the sort to support the fuel tank. b. Locate the support straps that secure the fuel tank to the vehicle. Loosen and remove. c. With the tank loose, reach up on top of the tank and un-clip and remove the factory fuel line quick connects. d. Lower the fuel tank. 11. Using a punch and hammer, hit the lock ring in a counter clockwise direction as viewed from the top. Continue until the lock ring can be removed.

9 6/15/2016 # D Dodge Cummins FlowMAX Lift Pump Kit (I-00329) Remove the factory pickup can/basket from the top of the tank. 13. With a flat head screw driver, release the two locking clips that secure the float. With the float out, you should have more room to work with.

10 6/15/2016 # D Dodge Cummins FlowMAX Lift Pump Kit (I-00329) With a sharp knife cut the plastic tube to release the hose off of the O.E. hose barb. Take caution to not cut into the plastic barb while doing this. DO NOT CUT INTO THE PLASTIC BARB.

11 6/15/2016 # D Dodge Cummins FlowMAX Lift Pump Kit (I-00329) Cut a 7 section of 3/8 fuel hose and carve a v-notch into the base of it using a razor blade or similar. 16. Remove the power and ground wires leading to the O.E. supply pump and remove supply pump from basket. Several small picks or allen keys may be used to retain the locking tabs out of the way.

12 6/15/2016 # D Dodge Cummins FlowMAX Lift Pump Kit (I-00329) Slip the hose onto the O.E. hose barb with the notched end into the bowl and secure using the supplied hose clamp. Ensure the hose inlet is not obstructed and secure the hose to the original supply pump frame using zip-ties or similar. 18. Re-attach the float. Drop the modified basket into the fuel tank and secure with the locking ring. 19. Plug in pump wiring harness and zip tie out of the way. Let pickup plug hang until fuel tank is lifted as seen in photo.

13 6/15/2016 # D Dodge Cummins FlowMAX Lift Pump Kit (I-00329) Lift the fuel tank back into the truck using a lift or jack. Ensure the wiring harness is connected to the pickup before the tank is lifted all of the way. Reattach the quick disconnect fuel fittings then secure the tank with the straps and reconnect the filler neck and breather. 21. Once everything is reconnected, cycle the ignition to ON several times before attempting to start the vehicle. This primes the fuel pump which should purge some air out of the system. Once cycled several times, the vehicle can be started. 22. Allow the vehicle to run for several minutes and check for leaks at all connections. 23. Make certain that all fuel lines, wiring harness are fixed in place well. Flow Specifications Flowrate should be MINIMUM 14VDC OR Filling a 1 gallon container every 24 14VDC

14 6/15/2016 # D Dodge Cummins FlowMAX Lift Pump Kit (I-00329) Trouble Shooting If you experience any problems or difficulties with this kit, please contact the BD Technical Department at or fax at , between 8:00am and 4:30pm Pacific Time.