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INDUSTRIAL
Fuel Air Separation System
INSTALLATION MANUAL
DETROIT SERIES 60
ENGINES
®
Model Years 2003 - 2009
PLEASE READ
THESE INSTRUCTIONS
THOROUGHLY
BEFORE BEGINNING
INSTALLATION
Part No. A3SPBT403
Revised 8/05/2020
NOW WITH DEMAND FLOW
Proudly Made in the USA
www.airdogdiesel.com
1-573-635-0555 or
1-877-463-4373
Providing "Test Cell Performance" in "Real World Conditions" Since 1993!
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Related Manuals for Airdog DETROIT 60 Series
Summary of Contents for Airdog DETROIT 60 Series
- Page 1 INDUSTRIAL Fuel Air Separation System INSTALLATION MANUAL DETROIT SERIES 60 ENGINES ® Model Years 2003 - 2009 PLEASE READ THESE INSTRUCTIONS THOROUGHLY BEFORE BEGINNING INSTALLATION Part No. A3SPBT403 Revised 8/05/2020 NOW WITH DEMAND FLOW Proudly Made in the USA www.airdogdiesel.com 1-573-635-0555 or 1-877-463-4373 Providing “Test Cell Performance”...
- Page 2 Long-Lasting MicroGlass Media Long-Lasting Wire Mesh Media CARB Executive Orders D-595-3 & D-595U-4 permit the advertisement, sales and installation of PureFlow Technologies AirDog Diesel Fuel Systems in California on 2016 and older model year ® on-road diesel vehicles and off-road diesel vehicles/equipment.
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Page 3: System Overview
SYSTEM OVERVIEW Welcome to the AirDog Heavy Duty Industrial ® Fuel Air Separation System for Class 8 Trucks The AirDog , with ADVANCED FUEL AIR SEPARATION, DEMAND FLOW, ADJUSTABLE ® REGULATOR, LOW PRESSURE SENSOR with LED INDICATOR and the 4G-HD FUEL... - Page 4 Section 4…..…...........Selecting the Best Mounting Location Section 5……….…..........Mounting the AirDog & Bracket Kit ® Fuel Lines, Fittings & Low Fuel Pressure Sensor Section 6A................Fittings & Fuel Pressure Sensor Section 6B……..…...…......………..Fuel Line from AirDog to Engine ® Section 6C….….…..…..........AirDog Fuel Return to Tank ®...
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Page 5: Installation & Safety Guidelines
MAY VOID YOUR ENGINE WARRANTY. SAFETY GUIDELINES CAUTION: Chock the vehicle’s tires to prevent rolling. CAUTION: Disconnect the battery cables before proceeding with the AirDog installation. ® CAUTION: Wear safety glasses when operating power tools such as drills and grinders or when using a punch or chisel. -
Page 6: Installation Parts List
4A-2-04-06-06-S 3/8” Street Tee 4A-4-01-06-S #6 M JIC x 3/8” M NPT Straight Adapter 4A-1-02-06-06-S SBK-1000 Sandwich Bracket Kit Sandwich Mounting Bracket Kit for AirDog & Champ 002-3C-0010-SBF ® Includes: 1 Front - 1 Back & 002-3C-0011-SBB 1 Center Bracket... - Page 7 Class 8 Truck. ® This installation shows the AirDog mounted under the steering column ahead of the shock absorber. ® Plenty of room here! NOTE: Check for clearance with the tire turned both toward and away from the AirDog ®...
- Page 8 ® Section 4 Selecting the Best Mounting Location Selecting the Best Mounting Location, cont’d This picture finds space to mount the AirDog on a bracket ® in the location of the original primary fuel filter. This installation on a short nose “Day Cab”...
- Page 9 PureFlow Technologies, Inc. ® AirDog FPII-150 Detroit Series 60 2003-09 ® Section 5 Optional Bracket Kit OPTIONAL KIT AVAILABLE (PN: SBK-1000) NO DRILL Universal Sandwich Mounting Bracket Sandwich bracket comes with all hardware that is needed and NO DRILLING Sandwich bracket can be used in any combination of ways to fit your truck.
- Page 10 5-2. Loosely assemble the mounting brackets and filters to the AirDog ® 5-3. Hold the AirDog , with the brackets and filters attached, next to the frame at the selected ®...
- Page 11 WIRING, AIR LINES OR OTHER COMPONENTS LOCATED BEHIND THE FRAME RAIL. 5-6. Loosely assemble the mounting brackets to the frame. 5-7. Mount and loosely assemble the AirDog on the brackets. ® 5-8. After mounting the AirDog on the brackets, snug the fasteners to achieve a good relaxed fit.
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Page 12: Installation
® original fuel lines and fittings. Inspect the original fuel lines for size, length, and condition. If the fuel lines are in good condition and the correct size and length to adequately reach the AirDog , you ® may want to go ahead and use them. If any of the fuel lines need to be replaced, it is recommended that the fuel lines selected meet or exceed SAE 100R5 requirements. -
Page 13: Fuel Lines
® to the Transfer Pump on the Engine 6B-1. Connect the original fuel line from the primary fuel filter to the transfer pump to the AirDog ® out to “Engine” port. If the fuel line is not in good condition or the proper length to make the con- nection, replace it with a new fuel line. - Page 14 SECTION 6C: Installing the AirDog Return Line ® The AirDog returns entrained air & vapor to the fuel tank. It is best to connect the AirDog Air/Vapor ® ® return line directly to the engine fuel return line. Be sure to connect it after the pressure regulator.
- Page 15 AirDog return line ® directly to the fuel tank. Keep in mind that the #6 return line included with the AirDog is only long ® enough to connect to the engine return line at the engine.
- Page 16 ® 6D-1. Inspect the fuel supply lines that connect the fuel tank(s) to the primary fuel filter for size, length, and condition. If a fuel line has deteriorated or if it is too short to connect to the AirDog ®...
- Page 17 PureFlow Technologies, Inc. ® AirDog FPII-150 Detroit Series 60 2003-09 ® Section 7 Fuel Line Upgrade Section 7A: Series 60 Engines WITHOUT a Secondary Fuel Filter 7A-1. Disconnect the steel fuel line from the “FOR-SEAL” fuel fitting at the fuel “OUT” port on the transfer pump and remove OE Fuel fitting.
- Page 18 PureFlow Technologies, Inc. ® AirDog FPII-150 Detroit Series 60 2003-09 ® Section 7 Fuel Line Upgrade Installing the Series 60 Fuel Line Upgrade, cont’d 7A-6. Connect and secure one end of the fuel line assembled in step 4A-5 to the transfer pump fuel “OUT”...
- Page 19 PureFlow Technologies, Inc. ® AirDog FPII-150 Detroit Series 60 2003-09 ® Section 7 Fuel Line Upgrade Section 4B: Installing the Series 60 Fuel Line Upgrade, cont’d 7B-4. Measure and cut the length of the fuel line required to connect the transfer pump fuel “OUT” port to the secondary filter fuel “IN”...
- Page 20 PureFlow Technologies, Inc. ® AirDog FPII-150 Detroit Series 60 2003-09 ® Section 7 Fuel Line Upgrade Section 4B: Installing the Series 60 Fuel Line Upgrade, cont’d 7B-11. Measure and cut the length of fuel line required to connect the secondary filter “OUT” port to the 90°...
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Page 21: Wiring Harness
8-2. Route the AirDog wiring harness pump motor lead and the fuel pressure sensor lead to the ® AirDog unit. Connect the wiring harness pump motor lead to the AirDog unit pump motor lead. ® ® wiring harness fuel pressure sensor lead (lead with the green seal) to the 8-3. - Page 22 “HOT” when the key is in the “RUN” position. This could be either in a spare fuse holder in the fuse panel or on the ignition switch itself. Note: DO NOT connect the AirDog wiring harness relay trigger lead to a point that is ®...
- Page 23 THIS Battery Accessory Ignition DO NOT Connect Here INSTALLING THE AIRDOG WIRING HARNESS INDICATOR LIGHT ® Amber LED Indicator Light 8-7. Select a location on the dash that is easily visible to the driver. Remove the dash components as necessary to access the area behind the selected...
- Page 24 Remove the nut from the indicator light. You will have to slip one wire at a time (red wire first) through the center of the nut. 8-9. Remove backing from the double-sided tape on backside of the AirDog wiring harness ®...
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Page 25: Section 9: Initial Start Up Procedure
9-2. Pre-fill the water separator/pre-filter with diesel fuel up to the bottom of the nut plate. r 9-3. Turn the starter key to the on/run position. r 9-4. The AirDog should now be running and pumping fuel, bleed the fuel line to the engine by ®... - Page 26 Rub clean diesel fuel or oil on filter seals ® before installing to ensure a proper seal. It is not necessary to pre-fill the fuel filter with fuel, the AirDog ® will fill the filter and prime the system automatically. Follow the instructions on the filter for proper tightening procedures.
- Page 27 NOTES...
- Page 28 PureFlow Technologies, Inc. ® AirDog FPII-150 Detroit Series 60 2003-09 ® Copyright 2017 Bulletin No. 206-1-0403 © CD Patents, LLC Revised August 5, 2020 All Rights Reserved...
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