Having a Pump Issue? Run Through These Steps Before Calling Tech Support
SERVICE AND TROUBLESHOOTING
In the unlikely event that there is an issue with pump performance, here are some steps to follow before calling into Tech Support. If you have gone through these steps and you are still experiencing an issue, gather your serial number off the silver plate on the pump, and call tech support at (877)-421-3187 to speak to a technician.
A noisy pump is most likely associated with a restriction or aeration in the suction side of the pump. Some troubleshooting steps are as follows:
1. Check the fuel line for any cracks or damage. Cracked or damaged fuel lines will pull in air and affect pump performance and cause the pump to run loudly. Replace any cracked or worn fuel lines.
2. Check for any leaking fittings. Leaking fittings may also cause a suction leak. Properly torque any leaking fittings.
3. If you are troubleshooting a filtered pump, check to make sure the water separator drain valve is tight. Also make sure the filters are tight and sealing to the base.
4. Check for an inlet restriction. If it has been a while since the water separator has been replaced, it is possible it is plugging with debris and needs replaced. Replace the water separator. The Raptor-4G is equipped with an inlet screen to keep particles from jamming the pump. Remove the inlet fitting and inlet screen adapter to check for debris. Blow out debris and reinstall inlet screen adaptor and inlet fitting. DO NOT RUN THE PUMP WITHOUT THE INLET SCREEN!
5. Check for damaged/pinched O-rings. A damaged O-ring on the suction side of the pump will cause aeration and create excessive noise. There are O-rings under the “tombstone” or “circular” gerotor cap depending on what pump you have and if this is a filtered pump, there are O-rings between the filter base and the pump head. To inspect the O-rings under the cap, remove the four allen head cap screws using a 3/16 allen key wrench, remove the cap, and inspect the O-rings. If there are damaged O-rings, replace as needed. For the O-rings between the filter base and pump head, remove the water separator (the one with the drain valve) and remove the four allen head cap screws with a 1/4" allen key wrench and pull the pump head off the base. Inspect the O-rings and replace as needed.
6. If the previous steps fail to quiet down the pump, perform a bucket test to eliminate issues at the tank. To perform a bucket test, remove the suction line from the fuel tank, put it in a bucket of fuel, and run the pump. If the noise goes away, the issue is within the fuel tank or at the fuel tank connection. If the noise does not go away, get your serial number off the pump and call tech support at (877) 421-3187.
EXCESSIVE FUEL PRESSURE DROP UNDER ACCELERATION:
A pressure drop of a couple psi is to be expected. Excessive fuel pressure drops under acceleration can be associated with an inlet restriction and/or suction leaks as well. Run through steps 1-4 in the “NOISY PUMP” section. If pump pressure still drops excessively, get the serial number off the pump and call into tech support at (877) 421-3187.
PUMP LEAKS FUEL:
All AirDog products are equipped with O-ring boss style fittings that use an O-ring to seal the fittings to the pump. Here are some steps to follow in case the pump leaks fuel:
1. Verify the fittings are properly torqued. Refer to your installation manual for torque specs. If fittings are loose, properly torque them.
2. Clamp off the fuel lines to prevent fuel loss and remove the “tombstone” cap from the bottom of the pump by removing the four 3/16 allen head cap screws. Inspect the O-rings for any damage. Replace any damaged O-rings with ones from the O-ring service kit that came with this pump. Be sure the O-rings are completely seated in the grooves, or damage to the O-rings may occur when re-installing the cap.
3. On a filtered pump, there are O-rings between the tower and the filter base. If these are pinched/damaged, they can leak. Clamp off the fuel lines to prevent fuel loss, remove the water separator. Remove the four allen head cap screws under the filter with a 1/4" allen key. Remove the motor tower from the base and inspect the O-rings. Replace as needed.
4. If fuel appears to be leaking between the mounting plate and the pump for a Raptor or between the filter base and pump head and the all the O-rings are good, get the serial number off the pump and call the tech department at (877) 421-3187.
PUMP DOES NOT RUN:
A no pumping situation can be associated with either an electrical or mechanical issue. Here are some steps to run though to identify the issue:
1. Inspect the inline fuse. If the fuse is blown, replace the fuse. If the fuse blows immediately, go to the next step. If the fuse is not blown, go to step 6.
2. A fuse that blows immediately indicates a possible jam in the Gerotor. To inspect the Gerotor, remove the four 3/16” allen head cap screws and remove the “tombstone” cap or “circular” cap, depending on the pump, and remove the gears. The gears may fall out, so be take care when removing. If the gears to not fall out, use a magnet to remove the gears.
3. With the gears out, replace the fuse and key on the truck to turn on the pump. If the pump still blows the fuse, call into tech support with your serial number (877) 421-3187. If the fuse does not blow, continue to the next step.
4. Spin the removed gears in your hand to verify free movement. If the inner gear does not move within the outer gear, separate the two and clean out any debris present. Once the gears are clear of debris, lubricate them with clean motor oil, reinstall them, be sure the O-rings from the cap are in the correct place in the grooves, and reinstall the cap using the previously removed cap screws.
5. After re-installing the gears and the fuse still blows, get your serial number and call tech support (877) 421-3187.
6. Verify there is 12 volts reaching the pump by disconnecting the Deutsch 2 pin connector at the pump and measure voltage across the pins on the harness side. For some trucks you must bump the starter to get the pump to cycle on for 30 sec. If there is power at the pins and the pump does not run, grab the serial number off the pump and call into tech support at (877)421-3187.
1. Verify the pump is running. If the pump is not running, refer to the “Pump Does Not Run” section.
2. If the pump runs, clamp off the suction line to keep fuel spillage minimal and disconnect it from the pump. With the pump running, feel for suction at the pump fitting. If suction is felt, there is an issue with the suction line or tank pulling in air and continue on to step 3. If weak or no suction is felt at the pump, run through steps 3-5 in the “Noisy Pump” section. After running through those steps if suction is better, reinstall the fuel line. If suction is not better, continue to step 4.
3. Inspect the fuel line for any cracks and replace if necessary. If the suction line looks fine, perform a bucket test as described in step 4 of the “Noisy Pump” section. If the pump picks up fuel at that point, the issue is internal to the fuel tank suction tube.
4. If suction is still weak, get the serial number off the pump an call into tech support at (877) 421-3187.
1. Verify the pump has suction by running through the “No suction section.”
2. If the pump has suction, verify the fuel pressure by installing a fuel pressure gauge as described in your installation manual.
3. If the pump pressure is too low, adjust the fuel pressure as described in your manual to the pressure setting described in your manual.
4. If the pump performance does not improve and the previous checks have been verified, get the serial number off of the pump and call into tech support at (877) 421-3187.