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AIR DOG AND FASS PUMP USERS
INCREASE YOUR HORSE POWER AND FUEL PRESSURE
WITH YOUR P PUMP CUMMINS
* OFV050HP Use with moderately modified Cummins diesels.
* Fuel pressure range of 37 to 45 PSI.
* Raises fuel pressure at full power.
Do you experience low fuel pressure at wide open throttle (WOT) and just accept it as normal?
Anthony Reames, the technical manager at Air Dog, asked us to solve the low fuel pressure problem with the famous P pump. Cummins owners report that the fuel pressure drops to as low as 15 PSI during full throttle runs. We jumped on this technical request because we thrive on a challenge. Solving problems is what Tork Teknology is all about.
The first thing we did is throw all assumptions out the window. We found that in most cases, they can be very misleading. Our slogan, that we live by, is "one good test is equal to a thousand expert opinions". This is how we attack a problem.
After installing an Air Dog II DF165 on our '98 test truck, we routed the 1/2" feed line to an accurate flow meter and ran all the return fuel through an additional flow meter. The fuel pressure was monitored by a glycerine filled pressure gauge. The results (shown left) align exactly with proven hydraulic formulas. Fluid will flow a specified volume through an orifice at a specific pressure and specific gravity. Simply put, a fluid will flow more volume (gpm) as the pressure increases through the same size orifice.
You may have asked yourself why Air Dog and FASS equipped trucks will show good fuel pressure at idle and cruise but the pressure drops at full throttle, to as low as 15 PSI. Take a look at the photo above. The flow meter indicates diesel fuel flow of 1.09 GPM. This is the volume of fuel flowing thru the inlet orifice at the base of the overflow valve. (see photo right) Actaully it translates into 1.14 GPM (multiply number by 1.0495 correction factor) flowing into and out of the P7100 pump. That is the volume of fuel flowing back to the tank over the overflow valve. Yes, we tested the Bosch and TorkTek valves both. If you are using one of the old Bosch valves with the .168 inlet orifice, your fuel pressure will never allow you to win ANY competition event.
ELECTRIC PUMPS DO NOT WORK WELL WITH THE P PUMP
I'm not saying that the Air Dog and FASS are not good pumps. Both are quality pumps. The problem is the orifice leakage is too large and bypasses too much fuel to tank. This leakage produces low fuel pressure at WOT.
We now know that the inlet orifice on a standard overflow valve will flow 1.14 GPM back to tank. This is how it lowers your fuel pressure and kills your diesel performance! If you run a 100 GPH (gallons per hour) pump, you are pumping 1.66 GPM. (100 GPH divided by 60 minutes/hour = 1.66 GPM) You are losing 69% of your pump volume thru the overflow valve. That's almost 75% of the fuel doing no work at all! Let's do the numbers for the DF165 which is rated at 2.75 GPM. If you lose 1.14 GPM to tank, 41% of your pumps capacity is LOST. Let's suppose you use the DF200 which flows 3.33 GPM. 34% of the pumps capacity is doing nothing for your performance 12V Cummins.
It's easy to see why Cummins P pump users are showing low fuel pressure at WOT. Too much diesel fuel is pumped through the overflow valve and back to tank. This translates into low HP and torque performance numbers. It could make the difference between winning or going home defeated.
Another problem that we uncovered was at a very specific pressure, the fuel flow over the overflow valve can be dead headed. This can be dangerous as the P pump needs fuel flow to help keep it cool. If you set the pump pressure regulator to slightly less than the OFV setting, fuel flow and pump cooling STOP. Also if you adjust the OFV by adjusting the shims, stretching the spring or adjust the Tork Tek overflow valve, the same problem can exist. The solution had to cure low fuel pressure and eliminate any possibility of stopping fuel flow over the valve.
WHAT ABOUT INJECTION PUMP COOLING?
We know from testing the Cummins fuel system, with the stock lift pump, that the fuel flow is .6 GPM max at 2200 RPM. The engineers at Bosch spent a lot of R & D time to make sure the P pump stayed cool at the fuel flow the lift pump delivered. The Bosch P7100 injection pump will run without problems for 300 to 500,000 miles or more! There are commercial trucks that have seen 1,000,000 miles with the P pump and stock lift pump.
The smallest of the four valves is the OFV070HP. This valve is for super modified, race only trucks. The orifice will flow .58 GPM at 40 PSI. So, even with the smallest of the valves, you will still have the same cooling capacity as a stock system.
THE NEW HP OVERLOW VALVE - A TESTED SOLUTION
How did we test for a solution? We machined 12 prototype overflow valves with replaceable orifices, similar to Holley carb jets. The beta testers could now replace the jet with a smaller one to the point where the fuel pressure was aceptable at WOT. In other words, the fuel pressure remained constant from idle to full throttle. Each jet change and fuel pressure reading was documented on a chart. In addition, I made the same tests on our '98 Dodge Cummins 12V.
It became clear after the testing was complete, which sizes cured the problem. Each size created a fuel pressure range at WOT. We also discovered that a very small chage in orifice size will make a dramatic change in fuel pressure.
FUEL PRESSURE MAKES HORSE POWER
To illustrate how fuel pressure can affect diesel horse power and torque, one beta tester asked his brother to try the prototype valve on a dyno. The owner of Left Coast Diesel made a run with a standard OFV and then installed the prototype HP valve. The first thing he noticed was consistent fuel pressure across the RPM band. No other changes were made to the engine. He achieved a 27HP increase for 3 minutes worth of work. His power increased from 663HP to 690HP at 93 MPH. That 27 peak HP increase can be the difference between winning and losing.
This is what Chad had to say when he tried the new valve. "My truck for sure picked picked up power in the top end. It never really keeps spinning the tires when I open it up in overdrive at 70, but now they just spin to the point I let off because its still going sideways at 100mph".
Our original intention was to offer the valve as an overflow kit with 10 different jets, but the cost would be very EXPENSIVE at $150.00 each. We came up with a better product for MUCH less!
What fuel pressure should you be running? Here is a general rule to determine the fuel pressure you should be at. Multiply the governor spring rpm (in thousands) times 10. In other words, you want 10 PSI of fuel pressure per 1000 RPM of govenor speed. If you installed a 3K govenor kit, you need a minimum of 30 PSI at full power. A 4K kit requires 40 PSI at WOT. Remember, this is at full power, not idle or cruise.
The OFV050HP has the second largest orifice for street use. This valve is for moderately modified street performance trucks using an AirDog or FASS pump. Your Bosch P7100 has a #5 to #8 torque plate with a good exhaust system. You installed larger injectors and upgraded the turbo. Your truck is a daily driver but you want more power for towing, competition, and off road. Horsepower will be in the 350 to 450 range. Yes it can be used for P pump conversions on the 24V Cummins. Fuel pressure is in the 37 to 45 PSI range, at full power. If you are using the original Air Dog pump, it is factory set at 30 PSI. If you want higher fuel pressure, you will have to install a 40 or 50 PSI spring. Air Dog II's have an adjustable pressure regulator and don't require the spring option.
Do not use the HP valve on a stock fuel system! The valve is intended for P pump trucks using a FASS, Air Dog or high volume, performance fuel pump only.
You added fuel and exhaust options to make more power. Don't let low fuel pressure rob you of the HP you built into your Cummins. Order a Tork Tek OFV050HP today and see the difference it makes in performance of your Cummins. At $26.99, it will be the cheapest performance mod you ever made. ORDER TODAY!
Free Technical Advice
We are in the process of writing a six part article series on the diesel fuel system. Many of the examples used were based on the Cummins, but the principles will work on the Duramax and PowerStroke too. All of the formulas, on sizing the different components, also apply to gas engines as well. Each article covers a specific area of the diesel fuel system. Article number one deals with the the low efficiency of the Cummins lift pump. Article number two is a very in depth look into the inlet line and how it affects the horsepower that your engine can produce. Feel free to share these articles with your performance friends.
Posted by Vinnie Tabone on 19th Mar 2013
Put a 94 cummins in my 85 Chevy. Has 4K-GS, #4 plate, intake, Exhaust, Raptor 100GPM. The truck just didn't fell like it should. Changed out the over flow with the Tork 50HP one and it feels so much better. Before it was gutless, and i was afraid it was going to die everytime i came to a stop. Now it feels and sounds like a cummins. Took 10 mins to put in and off i went. Great product. worth every penny.
Posted by Jon Sklar on 6th Feb 2012
Finally getting some time to sit down and thank you. Awesome product and it did exactly what i needed it to do. I built a 2006 Ford F-250 with a 12 valve p-pump swap and a 6 speed. Running a high volume electric pump, 3000 gov. springs, 0 fuel plate and 17.5 degrees of timing. The stock OFV was worthless and the injection pump just wouldn't hold pressure. Truck wouldn't rev over 1800 rpm, made no power, and would barely start after it sat over night. A 2 minute swap with your performance valve and i have great pressure at any rpm, makes great power, starts perfect every time and gets 17-20 mpg running on 35" mud terrains. i also passed this info on to the guys i bought the swap parts off of, Ford-cummins.com, and told them they should get in touch with you and include one of your valves in every one of their swap kits. thanks again!
Posted by Brooks Knight on 4th Apr 2011
I recently added a Air Dog 150 to my truck. My stock overflow valve was bypassing at 20-21 psi. So I replaced it with the OFV050HP and now my pressure stays at 29-30 all the time which is what my Air Dog is set at.