INSTALLATION MANUAL MODEL FP-100 WITH OPTIONAL LOW PRESSURE WARNING LIGHT FOR 24 VALVE CUMMINS® POWERED ® DODGE TRUCKS READ INSTRUCTIONS THOROUGHLY BEFORE BEGINNING INSTALLATION. PUREFLOW® TECHNOLOGIES, INC.
JEFFERSON CITY, MO 65109 FAX (573) 635-0778 Installation Manual PUREFLOW® DIESEL SYSTEM AirDog™ PUREFLOW® DIESEL SYSTEM AirDog MODEL FP-100 Welcome to the PUREFLOW® DIESEL SYSTEM AirDog™ Air/fuel Separation, filtration and delivery system for the diesel engine. The installation of the AirDog™ can be made relatively easy by following the steps outlined in this manual. 1. Inventory the package components completely. Notify PUREFLOW® TECHNOLOGIES, INC. Immediately of any parts missing or damaged. 2.
Installation Manual PUREFLOW® DIESEL SYSTEM AirDog™ TABLE OF CONTENTS Section 1 ........................................... AirDog™ OVERVIEW Section 2 ........................................... Parts List Section 3 ........................................... Safety Guidelines and Warnings Section 4 ........................................... Installation of Mounting Brackets, & AirDog™ Section 5 ........................................... Installation of Fuel Lines Section 6 .............................
Installation Manual PUREFLOW® DIESEL SYSTEM Section 1 AirDog™ OVERVIEW The PUREFLOW™ DIESEL SYSTEM AirDog™ Air/Fuel Separation System is the “missing link” between the fuel tank and the engine for diesel powered equipment. The AirDog™ delivers clean fuel to the engine free of virtually all air/vapor and at a positive flow. Thus, allowing the engine “test cell” performance and efficiency, while in “real world” use. The AirDog™ FP-100 is suitable for all stock and slightly modified 5.9 Cummin's® Diesels.
Installation Manual PUREFLOW® DIESEL SYSTEM Section 2 AirDog™ AirDog™ PARTS LIST Qty Description Part Number 1 AirDog™ PF100 1 Mounting Bracket 001-3C-0004 1 Installation Manual Optional Indicator Light Assembly Includes: Indicator Light, Dash Plate, Grommet & Pressure Switch 901-04-0001 1 Electrical Harness 5E-2-002 1 Mounting Hdwr Kit, Unit-to-Bracket Image Includes: 4 Il-A20C Socket Head Cap Screws, 1/4-20 x 1-1/4" Lg. Stainless Steel 3 4 3 4 3 2 1J-1-C20SN Bolt, Hex Hd.
Installation Manual PUREFLOW™ DIESEL SYSTEM Section 3 AirDog™ Dodge/Cummins 24 Valve Installation Accessory Kit Includes Frame Mounting Bracket with Backup Plate 3/8”-16x4-1/2” Hex Head Bolt 3/8” Lock Nut, 3/8” Flat Washer ½” ID Fuel Line 3/8” Quick Connect Fitting to ½” Pushlock Fitting 90 Degree #8 Flare x ½” ID Hose Barb Fitting #8 Flare (male) x 12 mm fitting w/Washer #8 Flare (female swivel) x ½” Hose Barb Fitting Filler Tube Return Fuel Fitting (1-1/2” OD) w/Hose Clamps 90 Degree #8 Swivel (female)
Installation Manual PUREFLOW® DIESEL SYSTEM Section 4 AirDog™ DODGE/CUMMIN'S 24 VALVE INSTALLATION PROCEDURES Installation of AirDog™ and Bracket to the Truck’s Frame Loose assemble mounting bracket to frame with backing plate using 3/8” x 4 ½” bolts, lock washers, and nuts included in the kit. Position mounting bracket so that its back is adjacent to the rear of the transmission tail shaft (above the transfer case skid plate on 4 x 4’s) to allow ease in changing of the fuel filter.
Installation Manual PUREFLOW® DIESEL SYSTEM Section 4 AirDog™ Install the two 3/8" NPT x #8 SAE flare fuel fittings into the AirDog™ ports marked "FUEL IN" & "ENGINE". Use diesel compatible thread sealer when installing these fittings. Note: Return fuel fitting comes factory installed to hold pressure regulator in place. Remove fuel filter and water separator from AirDogTM. Adjust AirDogTM to its bracket using 1/4-20 stainless steel socket head screws provided.
Installation Manual PUREFLOW® DIESEL SYSTEM Section 5 AirDog™ FUEL LINES THIS SECTION IS APPLICABLE TO STOCK AND SLIGHTLY MODIFIED ENGINES. Fuel Suction Line 5-1 From end of fuel line supplied with attached 'Quick Disconnect' fitting, measure and cut length of line required to connect fuel tank SUCTION port to AirDog™ inlet port marked "Fuel In". 5-2 Install #8 female swivel x 1/2" 'push lock' fitting into other end of fuel line (Ref. 5-1).
Installation Manual PUREFLOW® DIESEL SYSTEM Section 5 AirDog™ Fuel Suction Line Cont’d Quick connect Figure 5: Fuel tank To release quick-connect fitting from fuel tank suction tube, firmly push fitting toward the component being serviced while firmly holding the plastic retainer ring into the fitting. While the plastic ring is depressed, pull the fitting assembly from the suction tube. Use care to press the retainer ring squarely into the fitting body.
Installation Manual PUREFLOW® DIESEL SYSTEM Section 5 AirDog™ Fuel Supply Line 'RETURN TO TANK' FUEL LINE 5-5 Installing fuel 'Return to Tank' assembly in filler tube. Hose Clamp Filler Tube Filler Tube Fuel Return Fitting Fuel Tank Fuel Tank STEP 1. STEP 2. Cut filler tube as illustrated, removing 1½ inches. Loose assemble clamps on each end of filler tube. Insert 'Return To Tank' assembly in filler tube, rotate and position #8 flare fitting. Properly tighten clamps.
Installation Manual PUREFLOW® DIESEL SYSTEM Section 5 AirDog™ Fuel Supply Line 5-6 Installing fuel return line. Return Line # 8 Flare Fitting Return to tank Fuel suction line To engine STEP 1. STEP 2. Measure and cut length of 1/2" ID fuel line necessary to connect AirDog™ to 'Return To Tank' assembly in filler tube. Install #8 Swivel x ½ " pushlock fitting into each end of fuel line. Connect fuel line to AirDog™ port marked 'TANK' & #8 flare fitting on 'Return To Tank' filler tube assembly.
Installation Manual PUREFLOW® DIESEL SYSTEM Section 5 AirDog™ Fuel Supply Line from AirDog™ To Engine The AirDog™ fuel filter is made of the same Stratapore™ media as the OE filter. For optimum engine performance, it is recommended to by pass the factory filter head when installing the AirDog™ fuel system. 5-7 Remove original factory fuel supply line at the engine by removing the banjo fitting from fuel inlet port in VP44 injector pump or inlet port on Common Rail engine.
Installation Manual PUREFLOW® DIESEL SYSTEM 5-8 Section 5 AirDog™ Measure and cut length of line required to connect the 'Fuel to Engine' port on AirDog™ to 12mm x #8 flare (Ref. 5-7) on engine fuel inlet port. 1/2” Barb -to- #8 SAE Adapter 1/2 ID Flexible Hose Engine Engine Port Fuel Line Engine Figure 11: Connecting AirDog™ to engine Install 90o x 1/2" hose barb on end to engine. Install straight hose barb on end to AirDog™. Connect 90o fitting to 12mm x #8 flare on engine.
Installation Manual PUREFLOW® DIESEL SYSTEM Section 6 AirDog™ WIRING HARNESS The AirDog™ is equipped with a relay controlled wiring harness that connects directly to the battery and is activated by the OE fuel pump connection. Optional "low fuel pressure" warning light is available. 6-1 Connect the RED lead to the POSITIVE (+) post of the driver's side battery. Connect the GREEN lead to the NEGATIVE (-) post of the same battery.
Installation Manual PUREFLOW® DIESEL SYSTEM Section 7 AirDog™ INITIAL START PROCEDURE The AirDog™ is a self priming system, however, to prevent damage to a dry seal and reducing the life expectancy of the system, it is recommended to prefill the water separator with diesel fuel before initial startup. 7-1 Prefill the water separator with diesel fuel. 7-2 Turn the starter key to the on/run position.
