AirDog100 autopsy

[4tonGT40]

the motor looks like any/all electric motors ive ever seen. The carbon is most likely from the pump overheating and the brushes break down.Right? What kind of warranty does AD carry? I just bought one a few weeks ago (AD150) After seeing this thread im wondering if i should even install it. Is this common?

 

[09stroker]

Maybe it needed a filter change and it was putting a heavier load on the motor. Who knows

 

[Big Bore]

the motor looks like any/all electric motors ive ever seen. The carbon is most likely from the pump overheating and the brushes break down.Right? What kind of warranty does AD carry? I just bought one a few weeks ago (AD150) After seeing this thread im wondering if i should even install it. Is this common?

Possibly but the brushes didn't look that worn down.

Supposedly if you send in the registration card the AD will have a non transferable lifetime warranty.

 

[Big Bore]

Well first of all water in the fuel would not matter because the motor is not exposed to the fuel in any way.......
My brother had an airdog go out and when we took it apart a bunch of carbon crap came out of the motor. The small O-rings the seal the long bolts must have failed or been pinched on assembly cause there was straight up water in there.

I've been wondering if the adverse winter driving conditions here are unhealthy for the AD. It's mounted underneath, and gets a lot of icy road spray.

 

[Big Bore]

I can tell you a sump works better than a straw set up.

Yea but the first time I go get firewood it would get ripped right off the truck. A 5/8 tube with in tank mods is far superior to stock setup, and the AD is supposed to work even with that. And even the tube will have positive pressure most of the time. It isn't like there is a lot of head to lift.

 

[SEABEE08FX4]

Gotcha.

 

[psduser1]

Big Bore, have you tested the rotor and stator for continuity, ie for a short to ground? Those parts dont look " burned up" .

 

[kyle43335]

Wish it would explain why the system doesn't work.

You said the pump isnt protected and or water can get to the pump. You were wrong. Obviously you didnt know the path of fuel flow. I was pointing out how the system works..

 

[psduser1]

Water in fuel won't" burn up" the pump. It's a pump, used to transfer liquid. Water may corrode the pump internals, but that doesn't appear to be the case here.
Even the motor housing appears clean, as in not much water from road spray. Anything under a truck for 50k at home usually shows it, not sure about where BB is at.
Did I read in one of your threads in tech that somone mentioned a bad batch of these Airdogs?
May make a good prefilter head.

 

[kyle43335]

Water in fuel won't" burn up" the pump. thats a given...It's a pump, used to transfer liquid. Water may corrode the pump internals, but that doesn't appear to be the case here.
Even the motor housing appears clean, as in not much water from road spray. Anything under a truck for 50k at home usually shows it, not sure about where BB is at.
Did I read in one of your threads in tech that somone mentioned a bad batch of these Airdogs?
May make a good prefilter head.

Did the motor quite running?

 

[Big Bore]

You said the pump isnt protected and or water can get to the pump. You were wrong. Obviously you didnt know the path of fuel flow. I was pointing out how the system works..

Yea I know. I was repeating what the tech said.


I know the pump looks clean, I wiped it down before taking it apart to keep the internals from getting dirty. I also pressure wash the underside of my truck often to keep off the mud and whatever they spray on the roads.

 

[Southmike]

Sorry for long term reply.. I was making sure you did not have a clogged stock setup etc..

 

[Big Bore]

Did the motor quite running?

No, it didn't stop running, it pops the fuse almost immediately at key on WTS.

 

[Bean]

Life lesson, send in your AD warranty card so it will be under warranty when this happens.

 

[Big Bore]

Life lesson, send in your AD warranty card so it will be under warranty when this happens.

I'm not the original owner, I bought the truck a short time after the AD was installed. Making a lifetime warranty non transferable is a douchebag lawyer move. Requiring a card be filed is for products that have a specific time of warranty from time of purchase. Requiring a card for lifetime is stupid, and again, a douchebag lawyer move.

Also, I fail to see how doing all of that would change the fact I was left stranded on the side of the road with a trailer in the snow and lost a chance at some cheap firewood because the failed AD took out my primary pump. The AD warranty sucks and the AD is unreliable and has no provision to be bypassed if it fails, nor any way to warn if it isn't working.

 

[kyle43335]

I'm not the original owner, I bought the truck a short time after the AD was installed. Making a lifetime warranty non transferable is a douchebag lawyer move. Requiring a card be filed is for products that have a specific time of warranty from time of purchase. Requiring a card for lifetime is stupid, and again, a douchebag lawyer move.

Also, I fail to see how doing all of that would change the fact I was left stranded on the side of the road with a trailer in the snow and lost a chance at some cheap firewood because the failed AD took out my primary pump. The AD warranty sucks and the AD is unreliable and has no provision to be bypassed if it fails, nor any way to warn if it isn't working.

it actually does,if you install the low fuel pressure warning lightoke:

 

[Big Bore]

it actually does,if you install the low fuel pressure warning lightoke:

If the main harness fuse is blown, what would power the light?

It really needs an indicator for the pump itself. A small monitor panel with dead pump light and low fuel pressure light with their own fused sources. That would be doing the customer a great service.

 

[kyle43335]

If the main harness fuse is blown, what would power the light?

It really needs an indicator for the pump itself. A small monitor panel with dead pump light and low fuel pressure light with their own fused sources. That would be doing the customer a great service.

its not a power light!!! its a pressure switch,that screws into the ad housing. its independent of the power harness. no pressure,the light comes on. pressure,no light!! airdog sells them to. ive install many of them,they work great!!! look into it.

or for the simplest solution. how bout a pressure gauge.

 

[Big Bore]

its not a power light!!! its a pressure switch,that screws into the ad housing. its independent of the power harness. no pressure,the light comes on. pressure,no light!! airdog sells them to. ive install many of them,they work great!!! look into it.

Does the light have a seperate power wire? I saw the two wires for it on the harness when I removed the AD. They looked like they got power from the main harness, the same one that powers the motor.

 

[TARM]

"Water caused the issue with the pump." While that certainly could happen to a pump in a properly setup AD I can not see it happening. You would also have likely seen the type of damage you see with pump cavitation. As has been said prior under vacuum its pulled thru the filter and perpulator perculator or whatever they call the vacuum stage I air removal part ( this is the part the FASS do not and can not have as its patented.)

From those pics after seeing a good number of burned out pumps as well as the few I personally had on my 7.3 until I switched to a Bosch it looks like a typical over-heating "thermal" failure.

That could have been from a jam but you not finding anything and the conditions of the parts rules that out most likely. My guesses are:
a defective motor or internal wiring
too higher of vacuum causing thermal overload

the following one happen way more IMO than people think:

improper voltage for the load making it to the pump.

It seems not very many people that are just basic back yard much have or use multimeter much. Its very possible you could have an issue in that area.

Smaller gauge wire , length of the wire run, and quality of wire and connectors effect how much of the full voltage reaches the pump. For every bit lost the amperage and thus thermal goes up to make up the loss of flow rate.

An improper or compromised ground can cause basically the same types of issues.

The alt itself not producing the voltage its suppose to.



Another thing as I am not sure how the current ADs do pressure reg but if its post second stage filter where it sees pressure then a clogged or under flowing filter could create a high load from excessive pressure.

Of course as I stated early on it could just be a defect in the pumps motor or its internal wiring. But its always a very good idea to confirm none of the other things listed above are not present or an issue as you will likely be having a repeat of the issue if not just with the hp pump by itself if no lift pump is reinstalled.

Personally if you like the idea of a lift pump to take the vacuum load off the HP pump a Carter 460o/4601 is diesel and marine rated. The pressure is low enough to not be an issue if you put the water sep after.

With that or if you ever or anyone else puts in AD FASS or any pump in a lift pump position there is a extra step that will help prevent a lift pump failure taking out your more costly main pump. Plumb and wire in a fuel pressure sensor and gauge after the lift pump but before the HP pump. As long as you see positive pressure you know the HP pump has no load from its feed or input side its only load is from building pressure post pump which is what its does best and is built for. You could set it up with a trip light if you wanted where a small red or yellow light trips in the cab if you lose pressure so you know you have a issue.

IMO on things that can cause costly damage things like warning lights are hard to beat. You may not notice a dead fuel pressure reading driving but a red or yellow light tripping and lighting up will grab your attention fast. Hopefully save ruining a set of costly injectors barrels and plungers.