I can barely write let alone draw...
I'm leaving for Wisconson on Friday to be a guide at Camp Jeep. But, I think both of you have my cell phone, feel free to call me and I can at least walk you through what I did on a part.
Wiring is pretty straight forward. Using the ATC for all new connections, you can see I used 6 ports.
1. fog lamps
2. reverse lights
3. CB and XM
4. power wire (for hot to switches)
5. aux fuel pump
6. racor heater
Ran 12v hot straight to switches (4) and to relays for 1, 2, 5 & 6. Wires to and from switches to relays, grounded everything local (relays are near the ATC so they went to it). Wires from relay to pump, relay to heater, relay to lights...Used #10 wire for all power (fuse to relay, relay to accessory, accessory to ground). #14 wire to and from relays. Heat shrunk all connections. I probably overkilled all of this, bigger wire than needed and separated out to more circuts than neccessary...
Routing fuel was a bigger PITA. 3/8 from tank to a bunch of fittings on the Racor (all I have local that carrys any kind of fitting is sLowes and HomeDespot and thier availability on special fittings is nill...So I ended up using several fittings and some flared copper pipe to go from a 3/8ths barb to a 3/4 compression fitting...there is likely a fitting just for that somewhere in the world....but not at the blue or orange boxes. See the setup in the pic). From the same fittings in reverse from the Racor to the Fuel pump, as I said in another post, this thing is loud. You will want to isolate well with rubber, and try to put it on the frame and not the body. From pump via 3/8 hose to the Pollak 6 way. This thing took some figuring, I can better discribe it's hook-up on the phone. I fortunately have an auxillary fuel filter installed so I have soft lines up by the motor I could tap into. From the Pollak you are now split from grease and from Dino, so you need to find your dino line and cut into it, putting the Pollak in the cut. Add grease line to other in port on Pollak. For the Return line you have to reduce the 3/8ths lines (no 5/16ths on my truck) to 5/16ths or the connection will leak (again, could not find a 3/8 barb to 5/16 barb reducer so it took a couple of fittings to get from one to the other). Into the Return on the Pollak from the motor, then split to dino tank, for the grease line Greasecar and Greasel both recomend just looping the grease return (after the Pollak) back to the line from the grease tank (before it hits the Pollak).
Make sure all your clamps are tight! Even the ones that don't leak fluid out will leak air in...Keith read on a board that the CTD hates air in the lines...Remember the fuel pump is a puller/sucker (not a pusher from the tank) so if there is any air getting into the system it will pull that faster than the fuel (think of trying to get that last little bit of drink out of the bottom of a glass using a straw...you get more air than drink). I kept having a 'run out of fuel' situation, didn't matter if I was on dino or grease...then it wouldn't start...
