11/6/2009 2005-08 5.9/6.7 Dodge Cummins FlowMAX Lift Pump Kit # 1050310B - 1-2005-08 5.9L/6.7L DODGE CUMMINS BD FLOWMax V2 LIFT PUMP KIT Installation Instructions P/N # 1050310B 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.
11/6/2009 2005-08 5.9/6.7 Dodge Cummins FlowMAX Lift Pump Kit # 1050310B - 2 - Kit Contents: 1500350-L 1500357 1500359 1500355 FLOWMAX Lift Pump Flat Washer Self Threading 3/8 Bolt Mounting Bracket Qty: 1 Qty: 3 Qty: 3 Qty: 1 1500356 1330149 1500361 1500311 Anti-Vibration Mount Hose Clamp Drill Jig -AN 8 ORB x 3/8 Barb Qty: 3 Qty: 8 Qty: 1 Qty: 2 1502019 1500358 1502030-P Dowdy Washer T-Bolt Clamp Metric Barb Adapter Qty: 1 Qty: 2 Qty: 1 1500309-B 1502021 1300529 1500340 FlowMAX Lift Pump Wiring Harness 3/8 Fuel Hose Self Tap Inline Fuel Strainer Qty: 1 Qty: 84 Qty: 1 Qty: 1
11/6/2009 2005-08 5.9/6.7 Dodge Cummins FlowMAX Lift Pump Kit # 1050310B - 3 - Optional Accessories: 1081130 - Low Fuel Pressure LED Alarm kit 1085220 X-Monitor Digital Gauge Package (2003-07) 1080156 Fuel Pressure Kit (X-Monitor Accessory) Required Tools: 5mm Allen wrench Drill 1/8 and 21/64 Drill bits Pliers 3/16 Flat Screwdriver 10 mm Socket or wrench Small Pipe Cutter Knife To Cut Fuel Hose 9/16 Socket or Wrench 7/16 Socket or Wrench
11/6/2009 2005-08 5.9/6.7 Dodge Cummins FlowMAX Lift Pump Kit # 1050310B - 4 - Installation: 1. Disconnect both batteries. 2. Raise the vehicle and support it safely. 3. Located the factory fuel filter. On the rear of the fuel filter, remove the banjo bolt and hard fuel line assembly. Note that you can not actually remove the hard fuel line at this time. This will be accomplished in a later step. 4. Using the supplied Barb Adapter (1502030-P), insert the Dowty washer (1502019) over the thread section of the Barb Adapter. Thread the Barb Adapter assembly into the rear of the filter housing. Do not over-torque as this is an o-ring seal. 5. Connect the supplied 3/8 hose (1502021) to the Barb adapter and secure with one of the provided hose clamps (1330149). 6. Route the 3/8 Fuel hose along the frame rail down to the approximate mounting location of the FlowMAX pump. DO NOT CUT HOSE AT THIS TIME. 7. From underneath the vehicle, locate the cross member bracket on the outside of the driver s frame rail. Position and tape drill template onto frame rail just about 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 21/64.
11/6/2009 2005-08 5.9/6.7 Dodge Cummins FlowMAX Lift Pump Kit # 1050310B - 5-8. 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.
11/6/2009 2005-08 5.9/6.7 Dodge Cummins FlowMAX Lift Pump Kit # 1050310B - 6-9. 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 should be pointed towards the fuel tank. Tighten the clamps around the motor body, rather than the aluminum pump head. Torque nuts to 80 inlbs. 10. Insert the ORB-Barb fittings to the inlet and outlet of the pump. Do not over tighten as they use an o-ring for sealing.
11/6/2009 2005-08 5.9/6.7 Dodge Cummins FlowMAX Lift Pump Kit # 1050310B - 7-11. With the pump mounted, cut the hard fuel line about 12 ahead 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. 12. Route the fuel line that you connected from the front of the vehicle to the outlet of the pump. Use a hose clamp to secure this connection. Trim to fit, the remainder of the hose will be used for the inlet of the pump.
11/6/2009 2005-08 5.9/6.7 Dodge Cummins FlowMAX Lift Pump Kit # 1050310B - 8-13. Cut the hard fuel supply line once again, this time about 8 before the inlet of the pump. This time you will need to use a tube cutter. Install a small section of hose, then the fuel strainer. Connect the outlet of the fuel strainer to the inlet of the pump which will be on the other side of the frame rail. 14. Secure each connection with a hose clamp. Use two hose clamps when securing the rubber hose to the hard line.
11/6/2009 2005-08 5.9/6.7 Dodge Cummins FlowMAX Lift Pump Kit # 1050310B - 9-15. You will now need to drop the factory fuel tank. Be very careful as a full fuel tank is very 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.
11/6/2009 2005-08 5.9/6.7 Dodge Cummins FlowMAX Lift Pump Kit # 1050310B - 10-16. Remove the factory pickup can/basket from the top of the tank. Note that there is a locking clip to secure the can/basket. 17. With the basket removed, use a hack saw blade and cut the three supports from the OE lift pump. Disconnect the factory power and ground wires from the pump. Tie these out of the way. DO NOT USE A ZIP TIE AS IT WILL DISENGRATE IN DIESEL FUEL. 18. 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.
11/6/2009 2005-08 5.9/6.7 Dodge Cummins FlowMAX Lift Pump Kit # 1050310B - 11-19. With a sharp knife, score the plastic tube to release the outer tube and expose the 3/8 barb. You should now be able to lift the OE pump out of the basket. DO NOT CUT INTO THE PLASTIC BARB.
11/6/2009 2005-08 5.9/6.7 Dodge Cummins FlowMAX Lift Pump Kit # 1050310B - 12-20. Use the supplied 3/8 hose and stainless hose clamp to attach the hose to 3/8 barb. You will need to trim the hose to the exact length so it sits flush with the bottom of the basket. BE SURE TO CUT THE HOSE AT AN ANGLE OR V-NOTCH THE BOTTOM, OTHERWISE THE HOSE WILL SUCTION TO THE BOTTOM OF THE BASKET. IF YOU CUT THE V-NOTCH TOO HIGH THEN THE TRUCK MAY RUN OUT OF FUEL PREMATURLY. 21. Re-attach the float. Drop the modified basket into the fuel tank and secure with the locking ring. 22. Lift the fuel tank back into the truck using the lift. Re-attached the factory fuel quick connects. Secure the tank using the factory support straps. 23. You will now need to locate the OE fuel pump trigger wire. This wire is located underneath the Total Integrated Power Module (TIPM), which is located on the passenger side of the driver s compartment.
11/6/2009 2005-08 5.9/6.7 Dodge Cummins FlowMAX Lift Pump Kit # 1050310B - 13 - Electrical Installations Locate the releasing clips on the side of the TIPM. Press the clips to release. Rotate the TIPM so that it is upside down. 2005 Trucks Only Locate Pin #7 on the C6 connector. (OR/RED). Cut this wire and attach the yellow wire to the cut section that is connected to the C6 connector. Re-attach the TIPM.
11/6/2009 2005-08 5.9/6.7 Dodge Cummins FlowMAX Lift Pump Kit # 1050310B - 14-2006-08 Trucks Only At the very bottom you will locate Connection C10. In position 18 you will locate an OR/RD wire. Cut this wire leaving enough wire length to manipulate the wire. You will need to connect to the cut wire on the same side of the connector. Connect the supplied wiring harness to this connection. Use the supplied connectors to make this connection. As an alternative, you can solder and heat shrink this connection. PIN 18 OR/RD
11/6/2009 2005-08 5.9/6.7 Dodge Cummins FlowMAX Lift Pump Kit # 1050310B - 15-24. Now that you have connected to the OE pump wire trigger VIA the TIPM, lay out the wiring harness, plug it into the new FlowMAX Fuel Pump, and place the positive and negative terminals in the appropriate battery terminals. Once the routing paths have been chosen and laid out, install the relay to the firewall with the use of the self tapping screw (P/N# 1300529). Attach relay to firewall 25. Wiring should be attached with the use of supplied tie wraps so that the wiring will be away from contacting hot surfaces and/or moving components. Once the wiring is attached and everything is in place the positive and negative terminals can be attached to the battery. 26. Make certain that all fuel lines, wiring harness are fixed in place well. 27. Lower the vehicle and re-install the battery cables. If you experience any problems or difficulties with this kit, please contact the BD Technical Department at 1-604-853-6096 or fax at 1-604-853-8749, between 8:00am and 4:30pm Pacific Time.
11/6/2009 2005-08 5.9/6.7 Dodge Cummins FlowMAX Lift Pump Kit # 1050310B - 16 - Trouble Shooting Wiring harness diagram If you have problems, complete the following tests or procedures, Clean and re-tighten battery terminals. Ensure there are no crimped/pinched sections of fuel line. Change Fuel Filter Check OEM connection to weather pack plug for 12V. Check that fuse in supplied harness near battery terminal is not blown. Check that all plugs are securely clipped together Check TIPM connection Check for plugged filter The pump should operate between 16 and 18psi with 14V at idle. If you have lower voltage the pump pressure will also be lower.
11/6/2009 2005-08 5.9/6.7 Dodge Cummins FlowMAX Lift Pump Kit # 1050310B - 17 - LIMITED WARRANTY STATEMENT BD Engine Brake, Inc., Valley Fuel Injection Ltd., BD Diesel Performance, Turbocharger.net (the Seller ) warrants the following product(s): All products manufactured or rebuilt by the Seller are to be free from defects in material or workmanship which includes but is not limited to Turbochargers, Exhaust and Intake manifolds, Exhaust brakes, Intercoolers, Flex Plates, Transmissions, Torque Converters, Oil pans, Fuel pumps and systems, Electronic monitors and control systems. The Seller warrants to the original buyer of the product (the Buyer ) that it will repair or replace, free of charge, any product which has a defect in material or workmanship within the warranty period described below. Copy of original invoice is required to qualify for warranty. A defect is defined as a condition within the product that would render the product inoperable under normal conditions of use and service. The Seller s responsibility under this Warranty is limited to the repair or replacement, at the Seller s option, of any warrantable product returned prepaid with a complete service history and proof of purchase. A valid proof of purchase is a dated bill of sale or receipt. A Return Material Authorization (RMA) number, obtained in advance from a customer service representative of the Seller and the dated bill of sale or receipt, must accompany any product returned by the Buyer for warranty determination. The Seller will be the final authority on the approval of all warranty claims hereunder. The issuance of a RMA number does not represent an approval of a warranty claim. All repaired or replaced products will be returned to the Buyer freight collect. Accepted warranty products, which have been replaced, will become the sole property of the Seller. Until the Seller has approved a warranty claim, the Buyer will be responsible for all costs. Replacement parts and the labor costs incurred by the removal and replacement of the product while performing warranty work will be the responsibility of the Buyer. In no case does the obligation of the Seller exceed the original purchase price of the product as indicated on the original bill of sale or receipt. Under no circumstances will the Seller be liable for any travel time incurred in diagnosis for defects, or any other contingent expenses. Once the claim is approved and with in a 1 year period of original purchase Labor costs incurred will be considered for the removal and replacement of an eligible part while performing warranty work, at a rate of 55.00 per hour at authorized centers with prior approval of the Seller. Freight is FOB Abbotsford, B.C. Canada. To the extent permitted by law, the Buyer hereby waives all rights other than those expressly set out herein and acknowledges that this warranty sets out the Buyer s exclusive remedies with respect to products covered by it. This warranty shall not be extended, amended or varied except by written instrument signed by the Seller and the Buyer. The Seller will administer warranty requests on products sold by the Seller and not manufactured by the Seller by forwarding claims made by a Buyer under the manufacturer s warranty to the manufacturer. The final disposition of such claims will be made by the manufacturer and ruled by the laws of British Columbia, Canada. Customer assumes risk in purchasing product with in 30 days may return the product for exchange of other BD products or services only. No cash refunds are available. Please refer to Warranty time limitation per product.
11/6/2009 2005-08 5.9/6.7 Dodge Cummins FlowMAX Lift Pump Kit # 1050310B - 18 - NOT COVERED UNDER THIS WARRANTY This warranty is limited to the original purchaser of the product and is not transferable to subsequent owners. Specifically excluded from this warranty are failures of products caused by misuse, misapplication, negligence of the Buyer, accidents, modification, abuse, improper storage, installation, repair or operation, use of unauthorized parts or other mistreatment of the Buyer or his agent. Any competitive use, sled pulling, drag racing will void warranty on product. A sheared or twisted shaft, broken planetary gear sets, burned clutches, broken drive hubs, sun gear damage, cracked housings is not covered. Fluids and filters or damage caused from fuel or air contamination, BioDiesel, low fluid levels. This warranty does not cover deterioration of plating, paint or any other coating, linings or parts that are subject to normal wear and tear, such as light bulbs, fuses, bearing wear, seal wear, etc. If product is not installed by a trained and authorized BD dealer, installation facility must prove it is properly tooled and has certified training to have installed or to carry out repair of product. The Seller also disclaims any liability for incidental or consequential damages including but not limited to, repair labor, rental vehicles, hotel cost or any other inconvenience cost. To the extent permitted by law, this warranty is in lieu of all other warranties or guaranties, either expressed or implied, included the implied warranties of merchantability and fitness for a particular purpose and shall not extend to any Buyer or to any person other than the original purchaser residing within the boundaries of the continental U.S. or Canada. As well the seller is not responsible or obligated to update previously manufactured parts that are currently under the above warranty. NOTE THAT THIS GUARANTEE WILL BE VOID IF THE USER BREACHES THE CONDITIONS IN THE SECTION LABELED NOT COVERED UNDER THIS WARRANTY AND IS ONLY APPLICABLE ON THE PRODUCTS THE SELLER MANUFACTURES. DISCLAIMER OF LIABILITY Other than as expressly set forth herein, the Seller, together with its distributors, jobbers and dealers shall in no way be responsible for the product s proper use and service. In no event shall the Seller be liable for any special, incidental, indirect or consequential damages of any kind or nature, whether or not the Buyer was advised of the possibility of damage, arising or resulting from the use or performance of the product, and the Buyer hereby waives any and all such claims. The Buyer acknowledges that he/she/it is not relying on the Seller s skill or judgment to select or furnish goods suitable for any particular purpose and that the Seller has no liability that will extend beyond the scope of the limited warranty contained herein, and the Buyer hereby waives all remedies or liabilities, expressed or implied, arising by operation of law or otherwise, (including, without limitation, any obligations of the Seller with respect to fitness for any particular purpose; merchantability; and special, incidental, indirect or consequential damages) or whether or not occasioned by the Seller s negligence. The Seller disclaims any warranty and expressly disclaims any liability for personal injury or damages related to the Buyer s use of the product. The Buyer acknowledges and agrees that the disclaimer of any liability for personal injury is a material term for this Agreement and the Buyer agrees to indemnify the Seller and hold the Seller harmless from any claim related to the product and its use or performance. Under no circumstances will the Seller be liable for any damages, liabilities, costs or expenses incurred as a result of by reason of the use, performance or sale of the product, including without limitation, any damages, liabilities, costs or expenses incurred by reason of the Buyer s negligence related to those uses of the product as a result of the removal of the speed limiter. The Seller assumes no liability regarding the improper installation or misapplication of the product. It is the installer s responsibility to check for proper installation, and, if in doubt, contact the manufacturer.
11/6/2009 2005-08 5.9/6.7 Dodge Cummins FlowMAX Lift Pump Kit # 1050310B - 19 - Limited Warranty Details Parts Labour Product Name (Months/Miles) 1 (Months/Miles) 1, 2 Notes Torque Converters (Dodge) 36/ 150,000 12/12,000 No Race abuse covered Torque Converters (Ford & Allison) 36/ 150,000 12/ 12,000 No Race abuse covered Transmissions 36/ 150,000 12/ 24,000 No Race abuse covered Race Transmissions 12/ 24,000 Not Eligible Valve / Accumulators Bodies 12/ 24,000 12/ 24,000 Transmission Pans 36/ 150,000 Not Eligible Auto / Torq / Towloc s 12 / 24,000 Not Eligible Flex Plates 36/ 150,000 Not Eligible Injectors & Injection Pumps 12 / 24,000 12/ 24,000 Race Pumps 90 days parts/no labour Tuners and Chips Manufacturer 3 Not Eligible X-Monitor / Cool Down Timers 12/ 24,000 Not Eligible Intake / Exhaust Manifolds 36/ 75,000 Not Eligible Exhaust Kits 24 Months Not Eligible Surface rust not eligible Turbo Guards / Boost Builders / Waste Gate Kits 12/ 24,000 Not Eligible Intercoolers / Hoses / Clamps 12/ 24,000 Not Eligible Transmission Coolers Manufacturer 3 Manufacturer 3 Manual Transmission Clutches Manufacturer 3 Manufacturer 3 Short Shifters 12/ 24,000 Not Eligible Engine / Head Stud kits Manufacturer 3 Manufacturer 3 Engine Brakes 24/ 24,000 12/ 24,000 Steering Stabilizers / Sway bars 12/ 24,000 Not Eligible Boost Coolers Manufacturer 3 Manufacturer 3 Gauges and Mounts Manufacturer 3 Manufacturer 3 Performance Turbos 12/ 12,000 Not Eligible FlowMAX Fuel Pumps 60/ 75,000 Not Eligible Auxiliary Fuel Pumps 12/ 12,000 Not Eligible A Return Material Authorization (RMA) number, obtained in advance from a customer service representative of the Seller and the dated bill of sale or receipt, must accompany any product returned by the Buyer for warranty determination. 1 Warranty is based on whichever occurs first (Months or Mileage). 2 Prior approvals must be given to qualify for labour reimbursement. 3 As per Manufacturer s warranty