Airdog DETROIT 60 Series User manual

INDUSTRIAL

Fuel Air Separation System

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INSTALLATION MANUAL

DETROIT SERIES 60®ENGINES

Model Years 2003 - 2009

Part No. A3SPBT403

NOW WITH DEMAND FLOW

Providing “Test Cell Performance” in “Real World Conditions” Since 1993!

Proudly Made in the USA

www.airdogdiesel.com

1-573-635-0555 or

1-877-463-4373

PLEASE READ

THESE INSTRUCTIONS

THOROUGHLY

BEFORE BEGINNING

INSTALLATION

Revised 8/05/2020

THE RIGHT CHOICE FOR YOUR DIESEL ENGINE

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 o-road diesel vehicles/equipment.

Low Fuel Pressure Switch

and LED Indicator

Lets you know when to service

the fuel lter and water separator

before suering power loss.

NO MORE GUESSING!

4G-HD Fuel Pump

Pump shaft, stabilized with bearings on each end, holds the gerotor in virtually perfect

alignment for quiet running and extended longevity!

LoveJoy Coupler System

The LoveJoy Coupler System is

self-aligning and eliminates

virtually all vibrations.

Dual Port Pump

Balances the gerotor for quiet

operation and higher ows.

Protective Wire Screen

In water separator nipple.

6 Micron Particulate Filters

Long-Lasting MicroGlass Media

Water Separator/Prelter

Long-Lasting Wire Mesh Media

Bearings

Positive Air Separation

with primary air discharge port.

Demand Flow System

Easy installation, only one small line

connected to the engine return line to

return air/vapor to the tank.

Adjustable Regulator

For just the right fuel pressure.

INDUSTRIAL

Fuel Air Separation System

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

PUMP, is a premium fuel ltration and delivery system for the Detroit Diesel Series 60®engine,

model years 2003 thru 2009.

Specically, if the fuel pressure/ow to the injector, even with entrained air and vapor

removed, is insucient to totally ll the injector barrel on the up stroke of the plunger, a void

or low pressure will form that allows vapor to re-form within the injector. The result, “injector

lag”, is just another name for “delayed injection timing”. No matter what term is used, it leaves

the engine with increased fuel consumption, lost power, and increased exhaust emissions.

The Detroit Diesel Series 60® engine, model years 2003 thru 2009, utilizes “FOR-SEAL” ttings

with steel lines on the high pressure side of the transfer pump. These ttings have small passageways

and are restrictive to the fuel ow to the engine. To maximize the eciency of the 2003 THRU 2009

Series 60® engine, it is necessary to replace the restrictive fuel ttings and lines with the larger and

less restrictive lines & ttings.

The “UPGRADE” kit is NOT included with the Detroit installation kit, although the complete

and detailed instructions are included.

Contact PureFlow®Technologies at 1.573.635.0555 for additional information and ordering.

All AirDog®products are manufactured with a personal touch,

unsurpassed attention to detail, and the most stringent quality assurance!

TYPICAL INSTALLATION LAYOUT

The AirDog® requires only one small return line connected to the engine return line, for quick

and easy installations.

Pure Fuel to Engine

at Positive Pressure

Air/Vapor Return Line

Fuel Supply Line

Entrained Air in Fuel

from Agitation & Sloshing

Fuel Preporator®

Transfer Pump

PureFlow®Technologies, Inc.

AirDog®FPII-150 Detroit Series 60 2003-09

TABLE OF CONTENTS

Section 1……..….….…...........……................................…...…….....Table of Contents

Section 2…….........….………………….....................Installation and Safety Guidelines

Section 3……..……...…..……….….…..............….…………………...….….Parts List

Installation Procedures

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

Section 6D…............…….....……..........………………………..From Tank to AirDog®

OPTIONAL Fuel System Upgrade (Sold as Separate Kit, Not Included)

Section 7A......................................................Engines Without a Secondary Fuel Filter

Section 7B...........................................................Engines With a Secondary Fuel Filter

Section 8….....……....................…..……....………….….………....…..Wiring Harness

Section 9..……......….…...............….…..….................….………...……Initial Start Up

Maintenance

Section 10.……….........................…............…..............................………Filter Service

Section 1 Table of Contents

PureFlow®Technologies, Inc.

AirDog®FPII-150 Detroit Series 60 2003-09

Section 2 Installation & Safety Guidelines

The installation of your AirDog®can be made relatively easy by following the steps outlined in this

manual, and:

1. Inventory the package components. Immediately notify PureFlow® Technologies, Inc.,

of any missing or damaged parts.

2. Read the installation manual completely. Understand how the system operates and the

installation recommendations before beginning.

3. Proper location of the AirDog® on the vehicle is essential. Consider hazards presented to

the equipment by road debris and the elements.

4. The installation recommendations and guidelines contained herein are suggestions only.

Individual installations may vary.

5. Use diesel compatible thread sealer when installing ttings with NPT threads.

(Loctite® 545 Thread Sealer is diesel compatible.)

DO NOT REMOVE FACTORY INSTALLED SECONDARY FUEL FILTERS.

REMOVAL OF A FACTORY INSTALLED SECONDARY FUEL FILTER

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.

CAUTION: Do Not drill into or weld the top of the frame rail or within 1-½” of the frame rail

ange on the side of the frame rail.

CAUTION: Route the fuel lines and electrical harnesses keeping them away from hot exhaust

components and/or moving parts. Properly secure the fuel lines and electrical

harnesses to prevent chang.

If you are uncertain of any installation procedure, please call:

PureFlow®Technologies, Inc. at 573-635-0555 for technical assistance.

NOTE: The pictures used in this manual are for example only and may not depict

the exact components as found on your truck.

PureFlow®Technologies, Inc.

AirDog®FPII-150 Detroit Series 60 2003-09

Installation Parts List

Section 3 Parts List

1 #6 M JIC x 3/8” F NPT Return Fitting 4A-1-04-06-06-S

1 3/8” Return Tee 4A-4-08-06-06-B

1 #6 x #6 F Union Swivel 4A-1-22-06-06-B

2 # 6 F JIC Swivel x 3/8” Pushlock Hose Barb 4A-1-09-06-06-B

1 #6 F Swivel x #6 M JIC 90° Elbow 4A-2-04-06-06-S

1 3/8” Street Tee 4A-4-01-06-S

1 #6 M JIC x 3/8” M NPT Straight Adapter 4A-1-02-06-06-S

908-01-0403-RLFK Return Line Fitting Kit

1 Installation Manual 206-1-0403

1 AirDog®- with Serial Number Plate

FPII-150

1 Wiring Harness with Indicator Light 5E-2-010

1 Fuel Filter Monitor Light Plate 201-3-0004-S

1 3/8” Low Pressure Hose (Air/Vapor Return Line) - 7 ft Section 4C-1-02-05-010-7FT

1 Fuel Pressure Sensor 908-5C-9-007 or

908-5C-9-0010

ADFK-403 Installation Kit

Fuel Filter FF200-MG-6

Water Separator WS200-WS

QTY Description Part Number Image

908-00-0304 Frame Mount Kit

2 Mounting Bracket 002-3C-0003

002-3C-0004

2 #10 M JIC x 1/2” M NPT Straight Adapter 4A-1-01-10-08-S

2 #10 F JIC Swivel x #10 M JIC 90° Elbow 4A-2-04-10-10-S

2 #8 M JIC x 1/2” M NPT Straight Adapter 4A-1-01-08-08-S

2 #8 F JIC x 8 M JIC 90° Elbow 4A-2-04-08-08-S

1 #6 M JIC x 1/4” M NPT Straight Adapter 4A-1-01-A-C-SZ

1 Grommet 5J-1-1-04-2758

908-08-0800-UNIV AirDog®FPII Basic Fitting Kit - Universal Applications

SBK-1000 Sandwich Bracket Kit

1 901-08-0100-SB Hardware Kit Includes:

4 ea 3/8”-16 x 1” Socket Head Cap Screw 1M-C16SZ

3 ea 3/8”-16 x 3-1/2” Hex Head Bolt 1J-1-C56SZ

3 each 3/8”-16 x 4-1/2” Hex Head Bolt 1J-1-C72SZ

7 ea 3/8” Nut 1S-1-CSZ

7 ea 3/8” Lock Washer 1R-6-CSZ

1 Sandwich Mounting Bracket Kit for AirDog®& Champ 002-3C-0010-SBF

Includes: 1 Front - 1 Back & 002-3C-0011-SBB

1 Center Bracket 002-3C-0006PCB

OPTIONAL

1 901-08-0100 Hardware Kit Includes:

4 ea 3/8” x 1-1/4” Hex Head Bolt 1J-1-C20SZ

4 ea 3/8” Nut 1S-1-CSZ

4 ea 3/8” Lock Washer 1R-6-CSZ

4 ea 1/4-20 x 2” Socket Head Cap Screw 1L-A32C

4 ea 1/4” Lock Washer 1R-6-AC

4 ea 1/4-20 Hex Nut 1S-1-AC

PureFlow®Technologies, Inc.

AirDog®FPII-150 Detroit Series 60 2003-09

Selecting the Best Location to Mount the AirDog®

Installing the AirDog® at the proper location on the vehicle is most important. When deciding where

to locate the AirDog®, the following points should be considered:

• Best relationship to the transfer pump and the original primary fuel lter location

• Protection from the elements and road debris

• Accessibility for service

CAUTION: DO NOT mount the AirDog®directly on the engine.

Mounting the AirDog®directly on the engine will

immediately VOID your AirDog®Warranty!

Pictures below show examples of dierent AirDog®installations. There are many

variations in the arrangements of the components on the various trucks. With a

little ingenuity, the AirDog® can be successfully installed on any 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®.

Section 4 Selecting the Best Mounting Location

PureFlow®Technologies, Inc.

AirDog®FPII-150 Detroit Series 60 2003-09

Selecting the Best Mounting Location, cont’d

This picture nds space to mount the AirDog®on a bracket

in the location of the original primary fuel lter.

This installation on a short nose “Day Cab”

is on the driver’s side, behind the battery

box.

This shows space to mount the

AirDog®to the rear of the shock

absorber.

Section 4 Selecting the Best Mounting Location

PureFlow®Technologies, Inc.

AirDog®FPII-150 Detroit Series 60 2003-09

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 t your truck.

Sandwich bracket slides right over existing frame.

Section 5 Optional Bracket Kit

OPTIONAL KIT AVAILABLE (PN: SBK-1000)

PureFlow®Technologies, Inc.

AirDog®FPII-150 Detroit Series 60 2003-09

Mounting the AirDog® on the Truck’s Frame (Drilling Method)

5-1. Disconnect the fuel lines and remove the primary fuel lter.

NOTE: Mount the AirDog® as close to the location of the primary fuel lter as possible. This

will allow you, in most cases, to use the original fuel supply line from the fuel tank and also the

fuel line to the engine.

5-2. Loosely assemble the mounting brackets and lters to the AirDog®.

5-3. Hold the AirDog®, with the brackets and lters attached, next to the frame at the selected

mounting location. Check for clearance. If mounted between the frame and steer tire, turn the

steering wheel fully to the left and right to check for tire clearance.

Section 5 Mounting the AirDog®

5-4. Hold the AirDog® at the selected mounting location on the frame. Mark and center punch

each hole location.

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