Airdog CUMMINS ISX15 Installation Manual

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INDUSTRIAL

Fuel Air Separation System

INSTALLATION MANUAL

For Trucks Equipped with

CUMMINS

ISX15 Common Rail & X15

PLEASE READ

THESE INSTRUCTIONS

THOROUGHLY

Part No. A3SPBT453

BEFORE BEGINNING

INSTALLATION

Revised 3/25/20

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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Summary of Contents for Airdog CUMMINS ISX15

Page 1 INDUSTRIAL Fuel Air Separation System INSTALLATION MANUAL For Trucks Equipped with CUMMINS ISX15 Common Rail & X15 ® PLEASE READ THESE INSTRUCTIONS THOROUGHLY Part No. A3SPBT453 BEFORE BEGINNING INSTALLATION Revised 3/25/20 NOW WITH DEMAND FLOW Proudly Made in the USA www.airdogdiesel.com 1-573-635-0555 or 1-877-463-4373...
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.
Page 3 ® REGULATOR, LOW PRESSURE SENSOR with LED INDICATOR and the 4G-HD FUEL PUMP, is a premium fuel filtration and delivery system for the Cummins ISX15 Common Rail & X15 Diesel Engines. The “VACUUM FEED FILTER SYSTEM” currently on your engine passes entrained air to the engine and increases cavitation and vapor as the fuel filter plugs with use! With Air &...
Page 4 Section 2……..…...…....…...…....…Installation and Safety Guidelines Section 3……..……...………..…….…....……….……………..….Parts List INSTALLATION PROCEDURES Section 4…….…….…..………..…....Selecting the Best Mounting Location Section 5A & B………...…..………..Mounting the AirDog & Mounting Brackets ® Fuel Lines, Fittings & Low Fuel Pressure Sensor Switch Section 6A................Fittings & Fuel Pressure Sensor Section 6B….….…..…..…..........AirDog...
Page 5 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 7 ea 3/8” Lock Washers 1R-6-CSZ PLEASE NOTE Due to the many variables in components and arrangement of those components in the many different truck models, the AirDog installation kit contains only the basic fuel fittings ® needed to install the AirDog using existing fuel lines.
Page 7 NOTE: On various class 8 trucks, the manufacturer may use other than traditional steel braid fuel lines. These lines require special fittings. The fittings used with the original primary fuel filter are specific to the fuel lines used on the truck. When possible, mount the AirDog in the location that ®...
Page 8 WARNING! USE CARE NOT TO DRILL INTO OR DAMAGE ANY WIRING, AIR LINES OR OTHER COMPONENTS LOCATED BEHIND THE FRAME RAIL. Figure 10 Figure 11 5A-6. Loose assemble the mounting brackets and AirDog to the frame. After mounting the ® AirDog on the brackets, snug the fasteners to achieve a good relaxed fit, then finish tightening all of ®...
Page 9 PureFlow Technologies Inc. ® AirDog FPII-200 Cummins ISX15 & X15 ® ® Section 5 Mounting Brackets 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 ® Figure 14 Figure 15 5B-3. Loosely assemble the brackets to the plate and the AirDog to the brackets. ® 5B-4. After mounting the AirDog on the brackets, snug the fasteners to achieve a good relaxed fit, ®...
Page 11 . Therefore, for your convenience two extra ® 90º fittings have been included in the kit. 6A-1. Install the straight #10 JIC x ½” NPT fuel fitting in the AirDog fuel port marked “EN- ® GINE”. Use the 90º swivel fittings as needed when connecting the lines.
Page 12 6A-3. Install the ¼” NPT x #6 JIC Male Air/Vapor return fitting into the Air/Vapor return port marked “TANK”. Figure 18 Figure 19 6A-4. Remove the 1/8” NPT plug from the end of the pre-installed 45° fitting in the AirDog base. ® Install the fuel pressure sensor into the 45° elbow.
Page 13 ISX15 & X15 ® ® Section 6 Fuel Lines SECTION 6B: Installing the AirDog Return Line ® 6B-5. Measure and cut a length of fuel line necessary to reach from the Air/Vapor return fitting on the AirDog to the Special ISX Return Fitting on the engine.
Page 14 Section 6 Fuel Lines SECTION 6C: Connecting the AirDog to the Engine & Tank, cont’d ® 6C-2. Connect the fuel line from the tank to the fitting in the AirDog “FUEL IN” port. ® Figure 29 Figure 30 Connecting the AirDog to the Engine and Tank on vehicles with plastic fuel lines ®...
Page 15 7-2. 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. ® ® 7-3. Connect the AirDog wiring harness fuel pressure sensor lead (lead with the green seal) to the ®...
Page 16 “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 17 Battery Accessory Ignition DO NOT Connect Here INSTALLING THE AIRDOG WIRING HARNESS INDICATOR LIGHT ® Amber LED Indicator Light 7-7. 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 location.
Page 18 7-9. Remove backing from the double-sided tape on backside of the AirDog wiring harness ® indicator light dash plate. Install the dash plate and indicator light in the dash. Connect the AirDog ® wiring harness indicator light lead to the connector on the wiring harness.
Page 19 8-2. Pre-fill the water separator/pre-filter with diesel fuel up to the bottom of the nut plate. r 8-3. Turn the starter key to the on/run position. r 8-4. The AirDog should now be running and pumping fuel, bleed the fuel line to the engine by ®...
Page 20 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 21 NOTES...
Page 22 PureFlow Technologies, Inc. ® AirDog FPII-200 Cummins ISX15 & X15 ® ® NOTES ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________...
Page 23 PureFlow Technologies, Inc. ® AirDog FPII-200 Cummins ISX15 & X15 ® ® NOTES ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________...

This manual is also suitable for:

Cummins x15