Airdog II DF-100 Installation Manual

Fuel air separation system

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PureFlow AirDog®

AirDog®II DF-100 & DF-165

2005-Current Cummins Diesel

#16

PROTECTED BY

CANADIAN PATENT

US PATENTS

AUSTRALIAN PATENT

2,108,391

5,355,860; 5,746,184; 6,729,310

2005101054

NEW ZEALAND PATENT

532356

Additional Foreign Patents Pending in Europe, South America, Mexico, Japan, and China!

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Summary of Contents for Airdog II DF-100

Page 1 PureFlow AirDog® AirDog®II DF-100 & DF-165 2005-Current Cummins Diesel PROTECTED BY CANADIAN PATENT US PATENTS AUSTRALIAN PATENT 2,108,391 5,355,860; 5,746,184; 6,729,310 2005101054 NEW ZEALAND PATENT 532356 Additional Foreign Patents Pending in Europe, South America, Mexico, Japan, and China!
Page 2 PureFlow AirDog® AirDog® II DF-100 & DF-165 2005-Current Cummins Diesel SMALL and COMPACT 7” Long X 3.2” Wide X 10” Tall...
Page 3 2005 and up Cummins 24V diesel engine. The AirDog®II-4G Fuel Preporator® is an all in one premium high pressure fuel pump and filtration system for the 6.7L Cummins diesel. The system removes water, particulates, and entrained air from the diesel fuel.
Page 4 PureFlow AirDog® AirDog®II DF-100 & DF-165 2005-Current Cummins Diesel QUICK CONNECT COMPONENT OVERVIEW Provided in this kit is an OE style quick connection system. This system works to allow for a quick, clean, and professional install. SAE J2044 Quick Connect System The SAE J2044 quick connect system is the most commonly used system in the automotive industry.
Page 5 PureFlow AirDog® AirDog®II DF-100 & DF-165 2005-Current Cummins Diesel Section 1 Table of Contents TABLE OF CONTENTS Section 1……………………………….…………………..Table of Contents Section 2…………………………………Installation and Safety Guidelines Section 3…………………………….…..…..……………………….Parts List INSTALLATION PROCEDURES Section 4…………………….……………Fittings, Brackets, and Mounting FUEL LINES Section 5……………………………………………..….Fuel Line Assembly Section 6A………………………..……………………Supply Line 5.9L CP3...
Page 6 When installing the fuel module up-grade, be sure to drill the two additional ½” fuel ports as shown! When installing the AirDog®II fuel lines, be sure to connect the ORIGINAL ENGINE RETURN LINE to the fuel tank as it was from the factory when the installation is...
Page 7 PureFlow AirDog® AirDog®II DF-100 & DF-165 2005-Current Cummins Diesel Section 3 Parts List ® AirDog Parts List DESCRIPTION PART NUMBER IMAGE DF-100 ® AirDog DF-165 ® AirDog II Mounting Bracket 001-3C-0004 Mounting Hardware Kit, 901-61-0102-PM 010-3C-0002 Frame Bracket 010-3C-0001 Wiring Harness...
Page 8 PureFlow AirDog® AirDog®II DF-100 & DF-165 2005-Current Cummins Diesel ILLUSTRATION OF QUICK CONNECT COMPONENTS...
Page 9 (08J2044916UNF) fittings into clean motor oil and hand-thread into the “ENGINE” and “FUEL IN” ports of the AirDog®II-4G filter base as illustrated in figures 1, 2, and 3. Using a 3/4” deep socket, torque the fittings to 120in-lb or 10ft-lb.
Page 10 The photos in this manual may not be the same as your application. 4-5. Be sure to tuck the AirDog®II-4G as far up as possible without it rubbing on anything to prevent damage from road debris. The braket assembly is adjustible to achieve this.
Page 11 (figure 11) using the 3/8” bolts, lock washers, and nuts included in the kit. You will need two 9/16” wrenches. Properly torque all fastners! BE SURE to mount the AirDog®II with the “FUEL IN” port toward the rear of the vehicle (Figure 12). Figure 11...
Page 12 Figure 14 Figure 15 5-2. Now plug that fuel line with that fitting into the connection on the either the AirDog or the truck where the manual calls it out. 5-3. Run the fuel line along the frame away from any hot or moving parts such as exhaust or the driveshaft (Figure 16).
Page 13 PureFlow AirDog® AirDog®II DF-100 & DF-165 2005-Current Cummins Diesel Section 6A Fuel Lines (Supply Line 5.9L) Installing the Fuel Supply Line from the AirDog to the CP3 ® Injection Pump 5.9L ® When installing the AirDog fuel system, it is recommended to bypass the factory filter canister for optimum engine performance.
Page 14 6A-4. Run the fuel line along the frame as mentioned in step 5-3 to the “Engine” port in the AirDog®. Cut the fuel line to length and insert fuel line end FQC12S per step 5-1. Once the connector is installed, connect it to the male J2044 fitting in the “Engine”...
Page 15 PureFlow AirDog® AirDog®II DF-100 & DF-165 2005-Current Cummins Diesel Section 6B Fuel Lines (Supply Line 6.7L) Installing the Fuel Supply Line from the AirDog to the CP3 ® Injection Pump 6.7L ® When installing the AirDog fuel system, it is recommended to bypass the factory filter canister for optimum engine performance.
Page 16 Assemble one end of the suction fuel line (reference section 5) using fuel line end FQC12S. Once the end is pressed in, connect it to the J2044 fitting in the “Fuel In” port on the AirDog® A “click” will be heard when the fitting is properly connected. HS20...
Page 17 PureFlow AirDog® AirDog®II DF-100 & DF-165 2005-Current Cummins Diesel Section 6C (Continued) Fuel Lines (Suction Line from Tank) If you choose to remove the bed, properly support the truck bed to prevent serious injury or death! Figure 28 Figure 29 NOTE: The fuel tank and truck bed used for the pictures are examples only and may not be exactly the same as your tank.
Page 18 PureFlow AirDog® AirDog®II DF-100 & DF-165 2005-Current Cummins Diesel Section 6C (Continued) Fuel Lines (Suction Line from Tank) 6C-4. Refer to the installation instructions within the fuel module upgrade kit (P/N 901- 01-0510) and install the fuel module upgrade kit.
Page 19 6D-1. Assemble one end of the hose (Reference section 5) using Fuel line end FQC3890 and plug it into the “Return” J2044 fitting installed in the AirDog® (Figure 33). A “click” will be heard once the fitting is properly connected.
Page 20: Wiring Diagram
PureFlow AirDog® AirDog®II DF-100 & DF-165 2005-Current Cummins Diesel Section 7 Wiring Harness ® AirDog Wiring Harness Install WIRING DIAGRAM INDICATOR LIGHT LEADS* AirDog® MOTOR LEAD MALE POWER LEAD JUMPER PLUGS INTO FACTORY HARNESS FEMALE POWER PRESSURE FUSE HOLDER LEAD JUMPER...
Page 21 (Figure 37) Figure 37 7-3. Plug the AirDog® female power lead jumper into the top of the fuel module. 7-4. After a “click” is heard, slide the red locking clip over to lock the connection in place. 7-5.
Page 22 Black (-) lead to the Negative (-) post of the same battery. Red (+) Black (-) Figure 40 ® 7-7. Route the wiring harness to the AirDog and connect the 2 pin Deutsch connector to ® the corresponding connector on the AirDog Figure 41 NOTE: If the Optional Indicator Light is not used, secure the pressure switch lead to the wiring harness with a plastic tie.
Page 23 ® ® activate the AirDog II by turning the ignition switch to on If the AirDog II runs quietly, then excessive air from a loose fitting or leaking pre-filter seal or vapor from fuel flow restriction is most likely the reason for the excessive noise. Correct as necessary.
Page 24 It is suggested to check/drain the water separator every three months or as needed should you experience excessive ‘water in fuel’ conditions. When installing the water separator, be sure to clean the underside of the AirDog® base. Follow the instructions printed on the pre-filter for proper tightening procedures.
Page 25 Be very careful not to dislodge screws. Torque the cap screws in or pinch the O-rings. an opposing pattern. If there is damaged found to either the Gerotor, Gerotor pocket, or O-rings, call into AirDog® Tech Support for further assistance.
Page 26 Pressure Regulator Adjustment AirDog®II AND AirDog®II-4G ADJUSTABLE FUEL PRESSURE REGULATOR The AirDog®II and AirDog®II-4G rises to a new level of performance with an adjustable fuel pressure regulator machined from stainless steel with a double O-ring seal system and a soft seat piston.
Page 27 PureFlow AirDog® AirDog®II DF-100 & DF-165 2005-Current Cummins Diesel Section 12 Filter Maintenance Installing a New Filter 1. Clean the area around the filter head and groove or seal area. NOTE: Lubricate the seal with oil. Do not use diesel fuel to lubricate the seal.
Page 28 WATER SEPARATORS. Any PRODUCT that is in question of Warranty must be returned, shipped prepaid, to PureFlow AirDog. All Warranty claims are subject to the approval of PureFlow AirDog. If it is determined that a Warranty claim exists, PureFlow AirDog will, at its sole discretion, replace the defective PRODUCT with a comparable PRODUCT, repair the defective PRODUCT, or refund the BUYER”S purchase price in exchange for the PRODUCT.
Page 29 A period of 15 Calendar Days from the time of shipment is provided for the receipt of the defective unit at the PureFlow AirDog facility. Failure to return ship the defective unit to arrive within the defined time period will result in a charge of $250.00 against the customer’s credit card as the purchase cost of the defective unit.

This manual is also suitable for:

Ii df-165