Air Dog 100 Install

Air Dog 100 Install With Pics

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Original Writeup By Hvytrkmech

Here is the what and how I installed the Air Dog 100, there are pro's and con's, I will offer the most objective opinion I can. This will be a long detailed post

First off the wiring harness that came with the kit is the older out dated harness, it is NOT the same one as in 53Willy's pictures, it has one 3 prong triangle shape duetch connector for the A/D pump, the 2 spade connectors for the filter change indicator, battery connections, and a BLACK trigger wire, unfortunately the wireing was the last thing I did and my camera batteries were dead, so no pics of the actual harness.

Ok lets start off with the bracket, no way was I going to mount it the way the instructions called for, so i modified it accordingly

http://i232.photobucket.com/albums/ee168/Hvytrkmech/AirDoginstall008.jpg

http://i232.photobucket.com/albums/ee168/Hvytrkmech/AirDoginstall009.jpg

http://i232.photobucket.com/albums/ee168/Hvytrkmech/AirDoginstall010.jpg

Here is the bracket that is in the way from the factory,

http://i232.photobucket.com/albums/ee168/Hvytrkmech/AirDoginstall001.jpg

The unit on the frame,

http://i232.photobucket.com/albums/ee168/Hvytrkmech/AirDoginstall011.jpg

Different angle shots,

http://i232.photobucket.com/albums/ee168/Hvytrkmech/AirDoginstall013.jpg

http://i232.photobucket.com/albums/ee168/Hvytrkmech/AirDoginstall012.jpg

Continued, now that the A/D is mounted the fun begins, entire driveshaft, then tank removal,

http://i232.photobucket.com/albums/ee168/Hvytrkmech/AirDoginstall014.jpg

http://i232.photobucket.com/albums/ee168/Hvytrkmech/AirDoginstall015.jpg

Fuel pump removal, and draw straw install,

http://i232.photobucket.com/albums/ee168/Hvytrkmech/AirDoginstall016.jpg

http://i232.photobucket.com/albums/ee168/Hvytrkmech/AirDoginstall020.jpg

The joint sealer we use, (highly recomended),

http://i232.photobucket.com/albums/ee168/Hvytrkmech/AirDoginstall019.jpg

Continued, draw tube assembly and measurement, ok boy's, I dropped my tank with 20 gallons of fuel in it, using my h/d tranny lift centerd on the tank, after drilling the hole I had to cut the draw straw to size, ( pay attention here), the tank with fuel in it sitting center on the lift buckles the bottom of the tank inward giving you a false measurement, this is how I compensated for this, 1st measurement I cut 2" off the staw, then installed in the tank to get final measurement, at this point the straw was touching the bottom of the tank and the coupler was sticking up appx 1 gasket width (the rubber gasket that comes with the straw), I tightened it up and it touched the bottom of the tank, no problem though, as soon as I set the tank back up and relieved the pressure on the bottom of the tank it gave the required clearance, you could actuall push the tank bottom up and feel it hit the draw straw, the magic number for me was 2" with a VERY LIGHT grind to clean the edges of the draw tube. Here is the tube installed.

http://i232.photobucket.com/albums/ee168/Hvytrkmech/AirDoginstall023.jpg

Reinstall tank and begin the plumbing, here are some fitting I used, the one on the left is supplied with the kit, but the one on the right I had at my shop, if you are gonna mod the bracket then I would highly recommend getting at least 2 of these, that is all I needed.

http://i232.photobucket.com/albums/ee168/Hvytrkmech/AirDoginstall024.jpg

View of fitting installed,

Continued, the A/D 100 is designed to be plumbed through the factory fuel filter housing, thus the delema about the wiring harness. here are pics of the feed line going to the factory f/f housing, this is also where I used the 2nd hydraulic elbow that I had.

http://i232.photobucket.com/albums/ee168/Hvytrkmech/AirDoginstall045.jpg

http://i232.photobucket.com/albums/ee168/Hvytrkmech/AirDoginstall042.jpg

http://i232.photobucket.com/albums/ee168/Hvytrkmech/AirDoginstall041.jpg

Continued, now the wiring, I zip tied the relay to the factory harness on the fire wall, I coiled up and tied off the change filter indicator wiring and tucked it out of the way, I cut the pathetic inline glass bus fuse caddy they supplied with the harness and installed a weather tight sfe fuse caddy. I also cut off the o-ring connectors they use and soldered and heat shrunk my own on the battery wires.
Now the trigger wire that they send with this kit is a BLACK wire and is designed to go to the fuse panel, so it is appx 30" long, I wanted to use the factory trigger wire, an orange wire with red stripe, ( thanks Willy"s), and I had a location right next to the A/D on the frame to tie in, so I added 3' of the same diameter wire (16ga) and ran it in the wire loom for the A/D plug. The harness for the A/D power plug was about 3 ft longer than what I needed, so I ran it, measured it, cut and spliced it to the length that I wanted and tie it and the trigger wire in at the same location, Unfortunately these are the only pics I have of the wiring, (the trigger wire). The trigger wire is the ONLY wire that needs to be spliced into. I tied the orange with red stripe wire to my trigger wire then I took a piece of heatshrink tube and shrunk it on the end going to the tank, while the heatshrink tube was still hot I squeezed the end of it to make a water and air tight seal, (the pic of this was blurry, camera was dying at this point).

http://i232.photobucket.com/albums/ee168/Hvytrkmech/AirDoginstall032.jpg

http://i232.photobucket.com/albums/ee168/Hvytrkmech/AirDoginstall030.jpg

http://i232.photobucket.com/albums/ee168/Hvytrkmech/AirDoginstall034.jpg

Notice the completed splice on the top right of picture,

http://i232.photobucket.com/albums/ee168/Hvytrkmech/AirDoginstall035.jpg

http://i232.photobucket.com/albums/ee168/Hvytrkmech/AirDoginstall027.jpg

http://i232.photobucket.com/albums/ee168/Hvytrkmech/AirDoginstall039.jpg

Continued, all in all not a bad job, however I don't see it being done in 3 hours, at least not with any quality, It took me 14 hours without stopping one time.

The directions supplied are shotty at best, just simply not specific enough with very poor detail, (to generic). I know they are working on better instructions.

The pump assembly, and most related components are of top quality, the pump runs a little loud at start up but that is it, once the truck is running you cant hear the pump at all. Even though this pump is routed through the factory f/f housing and my GDP 2 micron f/f set up it still puts a rock solid 18 psi at the cps, (sweet). I think I will be eliminating the GDP 2 micron set up, and run the stock f/f housing with no filter, the jury is still out on it though.

I noticed once the truck fired up and the air bled out of the system, it idled a LOT quiter, acceleration seems smoother with less effort, the pinging/ nailing I had seems to be completely gone also, time will tell.

Even with the small problems I would have to give 2 thumbs up, all said and done. Here are some final install pics.

Thanks for viewing,

Tim

http://i232.photobucket.com/albums/ee168/Hvytrkmech/AirDoginstall037.jpg

http://i232.photobucket.com/albums/ee168/Hvytrkmech/AirDoginstall036.jpg

http://i232.photobucket.com/albums/ee168/Hvytrkmech/AirDoginstall038.jpg

--Iker42 16:52, 20 January 2009 (EST)