FUEL PREPORATOR FPII-150 The Original Fuel Air Separation System INSTALLATION MANUAL

Transcription

1 FUEL PREPORATOR FPII-150 The Original Fuel Air Separation System INSTALLATION MANUAL PLEASE READ THESE INSTRUCTIONS THOROUGHLY BEFORE BEGINNING THE INSTALLATION. Caterpillar 3406A, 3406B, 3406C, C7, C9, C12 Detroit 6V-71, 8V-71, 6V-92, 8V-92, Series 60 Volvo VED-12 Cummins N-14 Primary, 855 NTC International MaxxForce 13 NOW WITH DEMAND FLOW and ADJUSTABLE REGULATOR Providing Test Cell Performance in Real World Conditions Since 1993! PROTECTED BY CANADIAN PATENT US PATENTS MEXICAN PATENT 2,108,391 5,355,860; 5,746,184; 6,729, NEW ZEALAND PATENT AUSTRALIAN PATENT Additional Patents Pending in Europe, South America, China, and Japan!

2 FUEL PREPORATOR II Approved for Sale and Use in California by CARB! RETURNS AIR/VAPOR & FOAM TO THE TANK ADJUSTABLE STAINLESS STEEL PRESSURE REGULATOR POSITIVE AIR SEPARATION WITH FLOW DIVIDERS & PRIMARY AIR DISCHARGE PORT FUEL PREPORATOR II DEMAND FLOW FPII-150 TWO YEAR LIMITED EXPRESS WARRANTY NOTICE! To register your TWO YEAR LIMITED EXPRESS WARRANTY, please fill out and return the enclosed Product Registration/Warranty card with a copy of the original sales receipt to. CAUTION: Do Not mount the Fuel Preporator II directly on the engine! Mounting the Fuel Preporator II directly on the engine will immediately VOID your Fuel Preporator II Warranty! 2

3 SYSTEM OVERVIEW Welcome to the Fuel Preporator II Fuel Air Separation System for Class 8 Trucks The Fuel Preporator II, with Advanced Fuel Air Separation, DEMAND FLOW and a STAINLESS STEEL ADJUSTABLE PRESSURE REGULATOR is a premium fuel filtration and delivery system for your diesel engine. The Fuel Preporator II removes water, particulates and the air that becomes entrained in diesel fuel from sloshing and agitation from the fuel flow to the engine. The entrained air and vapor separated from the fuel is returned to the fuel tank through a small return line. The fuel flow to the engine s transfer pump is at a NET POSITIVE PRESSURE HEAD preventing cavitation and the formation of vapor thus overcoming the performance related problems from plugged fuel filters, high altitude operation and torque loss at higher engine RPM s. Air & Vapor are compressible! When Air/Vapor is present in a fuel injection system the pressure buildup and injection of fuel is delayed while the Air/Vapor is being compressed. This delay retards the injection timing causing a shorter power stroke and low power, increased fuel consumption and increased exhaust emissions. Preventing the formation of vapor from pump cavitation and removing entrained air from the fuel flow to the injectors restores Correct Injection Timing. Diesel engines equipped with the Fuel Preporator II can now perform as designed, delivering test cell performance while in real world use! products are manufactured with a personal touch, unsurpassed attention to detail and the most stringent quality assurance! TYPICAL INSTALLATION LAYOUT Figure 1 The Fuel Preporator II, with Advanced Fuel Air Separation, DEMAND FLOW and ADJUSTABLE PRESSURE REGULATOR, returns entrained air & vapor (foam) back to the tank. The Fuel Preporator II, with these NEW FEATURES, now requires only one small return line to only one tank for quick and easy installations. 3

4 Section 1 TABLE OF CONTENTS Table of Contents Section Table of Contents Section Installation and Safety Guidelines Section Parts List INSTALLATION PROCEDURES Section Selecting the Best Mounting Location Section Fuel Preporator II & Mounting Brackets Fuel Lines, Fittings & Low Fuel Pressure Sensor Switch Section 6A...Fittings & Sensor Switch Section 6B Fuel Line from Fuel Preporator II to Engine Section 6C Fuel Preporator II Fuel Return to Tank Section 6D From Tank to Fuel Preporator II Electrical Harness Section Electrical Harness Engine Specific Procedures Section Caterpillar 3406A, 3406B, 3406C, C7, C9, C12 Section Cummins N-14 & 855NTC w/ Pump Mounted Filter Section Detroit Series 60, 2003 and Up Initial Start Up Section Initial Start Up Maintenance Section Filter Service Recommendations Section Cleaning the Gerotor Assembly Section Pressure Regulator Section 15 Limited Warranties Statement Section Notes 4

5 Section 2 Fuel Preporator II The installation of your Fuel Preporator II can be made relatively easy by following the steps outlined in this manual, and: 1. Inventory the package components. Immediately notify PUREFLOW AirDog, 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 Fuel Preporator II 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 fittings with NPT threads. (Loctite 545 Thread Sealer is diesel compatible.) DO NOT REMOVE ANY FACTORY INSTALLED SECONDARY FUEL FILTERS. REMOVAL OF A FACTORY INSTALLED SECONDARY FUEL FILTER MAY VOID YOUR ENGINE WARRANTY. SAFETY GUIDELINES! Installation & Safety Guidelines CAUTION: CAUTION: CAUTION: CAUTION: CAUTION: Chock the vehicle s tires to prevent rolling. Disconnect the battery cables before proceeding with the Fuel Preporator II installation. Wear safety glasses when operating power tools such as drills and grinders or when using a punch or chisel. Do Not drill into or weld the top of the frame rail or within 1 ½ of the frame rail flange on the side of the frame rail. 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 chaffing. If you are uncertain of any installation procedure, contact for technical assistance. NOTE: The pictures used in this manual are for example only and may not depict the exact Components or Arrangement as found on your truck. 5

6 Section 3 Installation Parts List QTY DESCRIPTION Part Number IMAGE 1 Installation Manual Fuel Preporator II FPII-150 Parts List 2 Mounting Bracket 002-3C C Customer Service O-ring Kit N/A 1 #6 Return Hose Assembly (10 ft.) 4C N JIC F Swivel 90 Elbow Hose Fitting 4A S 1 Wiring Harness 5E Indicator Light Kit #10 JIC Flare x 1/2 NPT 4A B 1 #6 JIC Flare x ¼ NPT Fitting 4A-1-01-A-C-SZ 1 Frame Bracket Hardware Kit, Includes: 4ea 3/8 x 1-1/2 Hex Head Bolt, 4ea 3/8 Nut 4ea 3/8 Lock Washer 1 Mounting Bracket Hardware Kit, Includes: 4 Socket Head Cap Screws, 1/4-20 x 2" Lg. 4 Lock Washers, 1/4 4 Hex Nuts, 1/4-20 PLEASE NOTE (Included In) Due to the many variables in components and arrangement of those components in the many different truck models, the Fuel Preporator II installation kit contains only the mounting brackets, mounting hardware, wiring harness and basic fuel fittings needed to install the Fuel Preporator II. Including an assortment of items to accommodate all of the variables of the different truck models would be cost prohibitive and drive the cost of the product beyond reason. For these reasons, fuel Lines and additional fuel fittings are not included! For further details please contact your Class 8 Dealer or call (877) for a dealer in your area. 6

7 Section 4 Selecting the Best Mounting Location Selecting the Best Location to Mount The FUEL PREPORATOR II Installing the FUEL PREPORATOR II at the proper location on the vehicle is most important. When deciding where to locate the FUEL PREPORATOR II, the following points should be considered: Best relationship to the transfer pump and the original primary fuel filter location. Protection from the elements and road debris Accessibility for service CAUTION: DO NOT mount the FUEL PREPORATOR II directly on the engine. Mounting the Fuel Preporator II directly on the engine will immediately VOID your FUEL PREPORATOR II Warranty! Figures 2 thru 4 show examples of different Fuel Preporator II installations. There are many variations in the arrangements of the components on the various trucks. With a little ingenuity, the Fuel Preporator II can be successfully installed on any Class 8 Truck. Figure 2 shows the FUEL PREPORATOR II mounted under the steering column to the rear of the shock absorber while Figure 3, in a different truck, shows the FUEL PREPORATOR II mounted under the steering column ahead of the shock absorber. FIGURE 2 FIGURE 3 NOTE: Check for clearance with the tire turned both toward and away from the Fuel Preporator II! 7

8 Section 4 Selecting the Best Mounting Location Selecting the Best Mounting Location, cont d This installation on a short nose Day Cab is on the driver s side, behind the battery box. FIGURE 4 Section 5: Mounting THE FUEL PREPORATOR II ON THE TRUCK S FRAME! 5-1. Disconnect the fuel lines and remove the primary fuel filter. FIGURE 5 FIGURE Mount the Fuel Preporator II as close to the original location of the primary fuel filter 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. NOTE: Typically, the primary fuel filter is mounted directly on the frame. Mount the Fuel Preporator II on the truck frame. DO NOT mount the Fuel Preporator II on the engine! Mounting the Fuel Preporator II on the engine will immediately void your warranty. Secondary Fuel Filter Primary Fuel Filter FIGURE 7 Transfer Pump For Visual Reference Only ( B Caterpillar Engine) 8 Injector Pump

9 Section 5 Mounting the Fuel Preporator II Mounting THE FUEL PREPORATOR II ON THE TRUCK S FRAME! 5-3. Loose assemble the mounting brackets and filters to the Fuel Preporator II Hold the Fuel Preporator II, with the brackets and filters 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. Figure 8 Figure While holding the Fuel Preporator II at the selected mounting location on the frame, mark and center punch each hole location. WARNING! DO NOT DRILL INTO OR DAMAGE ANY WIRING, AIR LINES, OR OTHER COMPONENTS LOCATED BEHIND THE FRAME RAIL Drill a 3/8 hole at each of the 4 previously marked locations. Figure 10 Figure Loose assemble the mounting brackets to the frame Loose assemble the Fuel Preporator II on the brackets. Figure 12 9

10 Section 5 Mounting the Fuel Preporator II 5-9. After mounting the Fuel Preporator II on the brackets, snug the fasteners to achieve a good relaxed fit Properly tighten all of the fasteners. NOTE: These steps are necessary to prevent stress cracks from forming in the mounting brackets due to road vibration and bouncing. Section 6 FUEL LINE OVERVIEW Figure 13 Fuel Lines The Fuel Preporator II has been engineered to eliminate fuel related problems. It is important that the fuel lines are assembled and installed properly so as not to cause fuel flow restriction. When possible, use the fuel lines that are on the vehicle. This will reduce your installation costs and make the installation go much more quickly. 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 Fuel Preporator II in the location that will allow the use of the 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 Fuel Preporator II, 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. Fuel Supply Line: The fuel supply lines from the tank to the Fuel Preporator II and to the engine should be size 10, or at the absolute minimum, size 8. Air/Vapor Return Line: The Fuel Preporator II Air/Vapor return line can be connected to the engine s return line. Or, if it is preferred, the return line can be connected directly to one fuel tank. This kit includes the hose and fitting to the Fuel Preporator II. Primary Fuel Filters: It is most important that there are no fuel filters between the fuel tank and the Fuel Preporator II or between the Fuel Preporator II and the engine s transfer pump to plug and cause restriction. These filters must be removed from the system as part of the Fuel Preporator II installation. Secondary Fuel Filters: DO NOT REMOVE SECONDARY FUEL FILTERS. This is the filter between the transfer pump and the engine. 10

11 Section 6 Installing the Fuel Fittings and Low Fuel Pressure Sensor Switch! 6A-1. Remove the 1/8 NPT plug in the Fuel Preporator II base. The plug is located just below the motor end cap. Install the 45 0 elbow in this port. Install the pressure sensor switch into the elbow. IMPORTANT: Use diesel compatible thread sealer when installing NPT fittings. 6A-2. Install the straight fuel fitting, in the Fuel Preporator II fuel port marked ENGINE. Fuel Lines Figure 14 Figure 15 6A-3. Install a straight into the fuel inlet port next to the regulator. Figure 16 Figure 17 6A-4. Install the ¼ NPT x #6 JIC Male Air/Vapor return fitting into the Air/Vapor return port marked TANK. Section 6B: Connecting the Fuel Preporator II to the Transfer Pump on the Engine! 6B-1. Connect the fuel line that originally connected the primary fuel filter (See Step 5-1) to the transfer pump to the Fuel Preporator II out to Engine port. If the fuel line is not in good enough condition or the proper length to make the connection, replace it with a new fuel line! Figure 18 Example Only: Transfer Pump 11 Figure 19

12 Section 6 Fuel Lines SECTION 6C: Installing the Fuel Preporator II Return Line 6C-1. To install the FPII-150 Air/Vapor return line in most applications, simply install a T fitting in the engine return line between the fuel tank and engine. Figure 22 NOTE: A #6 Fuel Line is supplied with this installation kit. The installed fitting attaches to the Air/Vapor Return Port (Fig. 23). It is necessary to add the appropriate fitting to the open end to match the selected return option. 6C-2. If the fuel tank has an extra port, as shown in Figure 20, remove the plug. Figure 20 Figure 21 6C-3. Install an NPT x #6 JIC Flare fitting into the port. (Not Included In Installation Kit) 6C-4. Measure and cut the length of fuel line required, when properly routed, to connect the Fuel Preporator II Return Line to the new fitting in the fuel tank or the T. Figure 23 Figure 24 Fuel Preporator II Air/Vapor Return Port Return Port in Fuel Tank Showing the Return Line Connected 6C-5. Assemble the fuel line per standard procedures. 6C-6. Connect one end to the Fuel Preporator II return fitting and the other end to the fitting in the fuel tank or the T as appropriate. 12

13 Section 6 Fuel Lines Connecting the Fuel Preporator II fuel supply line to the Fuel Tank! 6D-1. Inspect the fuel supply lines that connect the fuel tank(s) to the primary fuel filter for size, length, and condition. When coming from the cross over fitting it is recommended the fuel lines from the cross over fitting to the individual fuel tanks be inspected. If the fuel line is too short to connect to the Fuel Preporator II or the fuel line has deteriorated, the appropriate corrections are suggested. 6D-2. If it is necessary to replace the fuel line, measure and obtain the proper length of fuel line required when properly routed and secured to make the connection from the fuel supply to the Fuel Preporator II. Assemble the fuel line per standard procedures. 6D-3. Route the fuel supply line from the fuel tank to the fitting on the Fuel Preporator II fuel inlet port marked IN. Figure 25 Figure 26 6D-4. Connect the fuel supply line from the fuel tank to the fitting. Secure the line to prevent chaffing and abrasion. 13

14 Section 7 ELECTRICAL HARNESS Electrical Harness The Fuel Preporator II is equipped with a relay controlled wiring. Additionally, the low fuel pressure warning light, to signal when a fuel filter change is needed, is standard equipment. The Fuel Preporator II relay controlled wiring harness. Figure 27 Fuel Preporator II Pump Motor Lead Pressure Sensor/Switch Lead Indicator Light Lead Positive Lead Negative Lead Mini Fuse Tap Relay Lead w/ single fuse Securing the Relay and Fuse Holder to the Vehicle 7-1. Secure the relay and fuse holder to the vehicle. This installation picture shows the relay mounted next to the steering column. Figure 28 Figure Route the pump motor and indicator light sensor lead to the Fuel Preporator II. Connect the 2 pin Deutsch connector on the end of the wiring harness to the pump motor lead. Figure 30 Figure Connect the lead with the green seal to the low fuel pressure sensor switch. 14

15 Section 7 Electrical Harness Routing the Indicator Light and Relay Trigger Lead The Low Fuel Pressure Indicator Light wiring leads must be routed through the firewall to Dash Board. The Relay Trigger Lead must be connected to a contact point that is HOT when the starter key is in the ON position. This could be either in the engine compartment or inside the dash such as a spare fuse holder in the fuse panel or on the ignition switch itself. Note: DO NOT connect the relay lead to a point that is HOT when the starter key is in the ACCESSORY ON position. To allow entry for the Indicator Light and Relay Trigger Lead through the firewall: 7-4. Most Peterbilts and Kenworths have access holes located below the steering column. Remove the plug and route the leads through the hole. Figure 32 Figure For other make trucks, drill a 5/8" hole in firewall to allow entry of the Relay Trigger Lead / Indicator Light harness into the cab. By the Steering Column Under the Dash Figure 34 Figure Route the red, relay trigger wire with the mini fuse tap and indicator light lead through the firewall. Be sure to seal the opening or install a grommet around the wire loom to prevent water leakage and protect it from chaffing. 15

16 Section 7 Routing the Indicator Light and Relay Trigger Lead, cont d! 7-7. Remove the mini fuse tap and connect the Relay Trigger lead (Red Wire) to a terminal on the ignition switch that when the ignition switch is in the ON or RUN position. Battery OR Electrical Harness Ignition Accessory Figure 36 Figure Route the relay trigger lead (Red Wire) to the fuse panel and insert the mini fuse link into a fuse holder that is HOT when the key is in the ON or RUN position. INSTALLING THE LOW FUEL PRESSURE INDICATOR LIGHT. Low Fuel Pressure Warning Light Kit! Figure Select a location on the dash board that is easily visible to the driver. Figure 39 Figure Remove the dash components as necessary to access the area behind the selected location. 16

17 Section 7 Electrical Harness INSTALLING THE LOW FUEL PRESSURE INDICATOR LIGHT, CONT D Drill a 1/2 hole at the selected location. Be very careful when drilling. Do not damage components located behind the dash. Figure 41 Figure Install the dash plate, remove the adhesive backing and match the corresponding dash plate hole with the 1/2" hole in the dash. Apply the plate to the dash. Figure Assemble the Indicator Light in the dash plate. Connect the two #10 female connectors on the wiring harness to the two spade connectors on the indicator light Re-install the removed dash components to their original position. CONNECTING THE POWER SUPPLY LEADS The power supply leads can be easily connected to the appropriate contacts on the alternator. However, any high amperage terminal that is always HOT is OK for the Positive + (RED) lead. Be sure the NEGATIVE (BLACK) lead is connected to a reliable Chassis Ground Route the Red & Black power supply leads to the alternator. Connect the Black (-) ground lead to the alternator Ground connection or reliable Chassis Ground. Figure 44 Figure Connect the Red (+) positive lead to the alternator Hot Lead going to the battery. 17

18 Section 8 Engine Specific Procedures Caterpillar 3406A, 3406B, 3406C, C7, C9, C12 Engine Specific Procedure SECTION 8: The Caterpillar Secondary Fuel Filter Procedure! All Caterpillar diesel engines are equipped with a secondary fuel filter mounted on the engine. The filter head usually has a Hand Primer Pump attached to make priming and starting the engine easier after filter changes. However, certain passage ways in the filter head and the valves in the hand primer pump are restrictive to fuel flow and negatively affect engine performance. Secondary Fuel Filter Small, Restrictive Passageway Restrictive One-way Check Valves B Figure 46 Figure 47 Figure 48 Hand Primer Pump One-way Check NOTE: In most cases, the filter head can be drilled out without removing it from the engine! You will need to the following parts to complete the Secondary Fuel Filter Procedure. The parts may be obtained by AirDog or from your local Caterpillar dealer. Parts Kit: (included w/ Unit Kit: A3SPBT401) 1 Cap - Hand Primer Pump Replacement 002-4G Gasket for Cap 002-4G Cap Screws 5/16-18 x 1 1/2 (FOR C12 ONLY) 1L-B24C 1 Cap Screws 1/4-20 x 1 1/2 (FOR C12 ONLY) 1L-A24C 18

19 Section 8 Caterpillar 3406A, 3406B, 3406C, C7, C9, C12 Engine Specific Procedure The Caterpillar Secondary Fuel Filter Procedures, cont d! Perform the following steps to improve fuel flow and engine performance Remove the hand primer pump and fuel filter from the filter head. Restricted Passageway Before Porting Process Un-restricted Passageway After Porting Process Figure 49 Figure Using a 3/8 bit, carefully drill out the passage that carries the fuel into the fuel filter and remove all burrs and shavings. Figure Using the same 3/8 bit, carefully drill out the cross passage from the cap. Remove all burrs and shavings. Install the cap and gasket Finally, install the cap and gasket on the filter head. Also, re-install the fuel filter. Figure 52 Figure 53 19

20 Section 9 Engine Specific Procedures Cummins N-14 & 855 NTC w/ Pump Mounted Filter Engine Specific Procedure SECTION 9: Cummins Pump Mounted Primary Fuel Filter Procedure! Primary Fuel Filters: It is most important that there are no fuel filters between the Fuel Preporator II and the engine s transfer pump that could plug and cause restriction. These filters must be removed from the system as part of the Fuel Preporator II installation. Figure 54 FROM THIS TO THIS Before connecting the Fuel Preporator II to your Cummins N-14 transfer pump, the primary fuel filter assembly mounted on the transfer pump should be removed. You will need to the following parts to complete the Pump Mounted Primary Fuel Filter Procedure. The parts may be obtained by AirDog or from your local Cummins dealer. Parts Kit: (included w/ Unit Kit: A3SPBT402) 1 Pulse Dampener 002-4G Pulse Dampener O-ring 002-4G Socket Head Cap Screws 1/4-20 x 3 1/4 1L-A50C 1 #8 JIC Flare x 1/2 NPT Fitting 4A S 20

21 Section 9 Cummins N-14 & 855 NTC w/ Pump Mounted Filter Engine Specific Procedure Cummins Pump Mounted Primary Fuel Filter Procedure, cont d! 9-1. Remove the 4 socket head cap screws securing the filter head to the transfer pump. Remove the primary fuel filter head from the transfer pump. Figure 55 Figure Install the two (2) grade 8 ¼-20 x 3 ¼ socket head cap screws supplied in the kit Install the Pulse Dampener using the longer ¼-20 socket head cap screws and washers previously removed in step 6-1. Be careful to properly install the O-ring in the pulse dampener! Figure 57 Figure Install a #10 JIC male flare x ¾ -16 UNF ORB fuel fitting in the fuel inlet port on the transfer pump. Properly tighten the socket head cap screws and fuel inlet fitting. 21

22 Section 10 Engine Specific Procedures Detroit Series & Up Engine Specific Procedure SECTION 10: 2003 & Up Detroit Series 60 Fuel Line Upgrade Procedure! The Detroit Diesel Series 60 engine, model years 2003 thru 2009, utilizes FOR- SEAL fittings with steel lines on the high pressure side of the transfer pump. These fittings have small passageways and are restrictive to the fuel flow to the engine. To maximize the efficiency of the Series 60 engine, it is necessary to replace the restrictive fuel fittings and lines. PureFlow AirDog #8 JIC x 14mm Passageway ID 14mm FOR SEAL Fitting ID Passageway Figure 59 NOTE: Secondary fuel filters are optional on Detroit Diesel Series 60 engines. Section 10A is for engines without secondary fuel filters. Section 10B is for engines WITH secondary fuel filters. Figure 60 Figure 61 Detroit Series 60 With Out Secondary Fuel Filter. Steel line carries fuel from transfer pump directly to the engine head. Detroit Series 60 With Secondary Fuel Filter Parts Kit: (included w/ Unit Kit: A3SPBT403) 2 #8 JIC 90º Field Serviceable Fuel Line End 4A S 2 #8 Straight Field Serviceable Fuel Line End 4A S 1 #8 JIC Male Flare x 3/8 NPT 90º Fitting 4A B 2 #8 JIC Male Flare x 14mm ORB Fitting 4A M 1 #8 JIC Male Flare x 16mm ORB Fitting 4A M 22

23 Section 10 Engine Specific Procedures Detroit Series & Up Engine Specific Procedure Section 10A: Up-Grade for Series 60 Engines Without A Secondary Fuel Filter! 10A-1. Disconnect the steel fuel line from the FOR-SEAL fuel fitting at the fuel OUT port on the transfer pump and remove the OE fuel fitting. Figure 62 10A-2. Install the new Ported 16mm x #8 JIC flare fitting in the transfer pump fuel OUT port. Figure 63 Figure 64 10A-3. Disconnect the OE fuel supply line from the FOR-SEAL fuel inlet fitting at the back of the head and remove the fitting. NOTE: You may remove the OE steel fuel line from the engine. 10A-4. Install the extended 3/8 NPT x #8 JIC flare fitting into the fuel in port vacated by the FOR-SEAL fitting. Use diesel fuel compatible thread sealer on all NPT threads. Extended 90º 3/8 NPT x #8 JIC Flare Fitting Figure 65 23

24 Section 10 Engine Specific Procedures Detroit Series & Up Engine Specific Procedure 2003 & Up Detroit Series 60 Fuel Line Upgrade Procedure, cont d! 10A-5. Measure and cut the length of fuel line required, when properly routed and secured, to make the connection from the transfer pump to the fuel inlet fitting at the back of the engine head. Assemble the fuel line per standard procedures. 10A-6. Connect and secure one end of the fuel line assembled in step 10A-5 to the transfer pump fuel OUT port. Figure 66 Figure 67 10A-7. Route and connect the new fuel line to the new #8 JIC flare fitting just installed in the back of the back of the engine head. Section 10B: Series 60 Engines With A Secondary Fuel Filter! 10B-1. Disconnect and remove the steel fuel line from the FOR-SEAL fuel fitting at the fuel OUT port on the transfer pump and from the secondary fuel filter, fuel in port. Figure 68 Figure 69 24

25 Section 10 Engine Specific Procedures Detroit Series & Up Engine Specific Procedure 2003 & Up Detroit Series 60 Fuel Line Upgrade Procedure, cont d! 10B-2. Replace the FOR-SEAL fitting in the transfer pump with the 16mm x #8 JIC flare fitting. Figure 70 Figure 71 10B-3.Replace the FOR-SEAL fitting in the secondary filter with the 14mm x #8 JIC flare fitting. 10B-4. Measure and cut the length of fuel line required to connect the transfer pump fuel OUT port to the secondary filter fuel IN port. Figure 72 10B-5. Assemble the fuel line with one straight and one 90º field attachable fuel line end fitting, as illustrated in Figure 47. Figure 73 Figure 74 10B-6. Attach the straight end to the transfer pump OUT port (Fig. 72) and the 90º end to the secondary fuel filter. 25

26 Section 10 Engine Specific Procedures Detroit Series & Up Engine Specific Procedure 2003 & Up Detroit Series 60 Fuel Line Upgrade Procedure, cont d! 10B-7. Disconnect the steel fuel line and remove the shut-off valve from the secondary fuel filter. Figure 75 Figure 76 10B-8. Install the 14mm x #8 JIC flare fitting in the out to engine port. 10B-9. Disconnect the OE fuel supply line from the FOR-SEAL fuel inlet fitting at the back of the head. Remove the steel line and fitting. Figure 77 Extended 90º 3/8 NPT x #8 JIC Flare Fitting Figure 78 10B-10.Install the 90º extended 3/8 NPT x #8 JIC flare fitting into the fuel in port vacated by the FOR-SEAL fitting. Use diesel fuel compatible thread sealer on all NPT threads. 10B-11. Measure and cut, the length of fuel line required to connect the secondary filter OUT port to the #8 JIC fitting just installed in the back of the engine head. 26

27 Figure 79 Figure 80 Engine Specific Procedures Fuel Preporator II Detroit Series & Up Section 10 Engine Specific Procedure 2003 & Up Detroit Series 60 Fuel Line Upgrade Procedure, cont d! 10B-12. Assemble the fuel line with a straight field attachable fuel line end fitting on each end. Figure 81 10B-13. Connect the one end of the new fuel line to the fuel OUT port on the secondary fuel filter. Route and connect the other end to the #8 JIC fuel fitting in the head. Figure 82 Figure 83 10B-14. Properly tighten the fuel line connections to the JIC fittings. Secure the fuel lines to prevent chaffing. 27

28 Section 11 SECTION 11: Initial Start Up Procedure The Fuel Preporator II is a self priming system. However, to prevent damage to a dry seal and reduce the life expectancy of the system, pre-fill the water separator/prefilter with diesel fuel UP TO THE BOTTOM OF THE NUT PLATE Pre-fill the water separator/pre-filter with diesel fuel up to the bottom of the nut plate Turn the starter key to the on/run position The Fuel Preporator II should now be running and pumping fuel, bleed the fuel line to the engine by loosening the fuel line connection at the engine fitting. As soon as the line is purged of air, tighten the fuel fitting. NOTE: Put a rag or shop towel around the fitting to prevent fuel splatter or spray. Catch all spilled fuel and dispose of properly. RECHECK ALL FUEL FITTINGS FOR LEAKAGE AND PROPERLY TORQUE. BE SURE ALL LINES ARE PROPERLY ROUTED TO PROTECT FROM EXCESSIVE HEAT AND SECURED TO PROTECT FROM CHAFFING AND ABRASION. RECHECK ALL ELECTRICAL LINES, SECURE AS NECESSARY Start your engine! Initial Start Up Initial rough idle is possible and is dependent on the amount of air in the fuel system from the installation. The Fuel Preporator II is preset to 18 PSI with a flow of 1 GPM. Fine tuning the adjustment for the optimum performance of your engine is at the owner s discretion. A pressure gauge is recommended when making the adjustments to assure the engine is not over pressured. 28

29 Section 12 Fuel Filter & Pre-Filter Section12: Filter Service Recommendations Plugging of either the fuel filter, water separator/pre-filter, or the wire screen in the water separator/pre-filter nipple will cause low fuel pressure and trigger the indicator light. Should you experience low pressure, first check the water separator/pre-filter for plugging. Then, should the low fuel pressure issue continue, replace the fuel filter. Fuel Preporator II Fuel Filter Fuel Filter Drain Valve Figure Micron Silicone Impregnated Water Separator Water Separator Drain Valve The Pre-filter Replace the water separator if it becomes damaged or permanently plugged. Servicing of the water separator simply requires draining at regular intervals. It is suggested to check/drain the water separator weekly or as needed should you experience excessive water in fuel conditions. When re-installing the water separator, be sure to clean the under side of the Fuel Preporator II base. Be sure the water separator/pre-filter is properly secured but, DO NOT over tighten and damage it. Follow the instructions printed on the water separator/pre-filter for proper tightening procedures. Caution: Be extremely careful to prevent any contaminates or debris from entering the water separator should it become necessary to remove it for cleaning! Even though the water separator/pre-filter nipple has a protective wire screen, debris could jam the Gerotor and cause the fuse to blow. This is not a warranty item. Should this happen, it is easily put back into working order. See the instructions on How to R & R the Gerotor for proper cleaning procedures. The Fuel Filter Replace the fuel filter after 20,000 miles of service OR when the LOW FUEL PRESSURE INDICATOR LIGHT turns on at higher operating RPM s, whichever comes first! When replacing the fuel filter, remove the fuel filter by turning it counter clockwise. Do Not prefill the fuel filter with fuel, the Fuel Preporator II will fill the filter and prime the system automatically. Follow the instructions on the filter for proper tightening procedures. CAUTION: Dispose of waste fuel and used filters properly to protect OUR environment! 29

30 Section 13 Gerotor & Pump Assembly SECTION 13: Cleaning Debris from the Gerotor Assembly Step 1 Step 2 Step 3 Remove the four (4) socket Carefully remove the O-rings, Remove and clean the gerotor. head cap crews that secure re-use as is possible. Be very careful not to damage the gerotor cap. the gerotor. Step 4 Step 5 Step 6 Remove the O-rings and clean Replace the center gear. Align and install the outer the inside of the gerotor pocket. gear and O-rings. Step 7 Step Install the gerotor cap. Be very careful not to dislodge or pinch the O-rings. 30 Loose assemble the cap screws. Torque the cap screws in an opposing pattern. (90 in-lb) NOTE: One Customer Service O-ring Kit is included with your purchase. Replace defective or pinched o-rings from this kit. Additional Customer Service O-rings Kits are available. NOTE: Should any installation problems arise, please call, toll free or , for assistance Monday Friday, 8:00 AM 4:30 PM EST.

31 Section 14 Pressure Regulator SECTION 14: How to Remove and Re-install the Pressure Regulator! The Adjustable Pressure Regulator is made of all stainless steel components, except for the viton O rings. Regulator Components A - Regulator Adjustor Screw B - Jam Nut C - Regulator Base Nut Figure 85 D Regulator Spring E Regulator Plunger STEP 1 STEP 2 STEP 3 E D C A B Loosen Jam Nut B and regulator base nut C. Turn Adjustor Screw A Counter clockwise to remove the assembly. Remove the Adjustor Assembly from the Fuel Preporator II base. Be careful to not damage the O rings or lose the regulator spring or plunger. STEP 4 STEP 5 STEP 6 Be sure the Regulator Plunger and Spring are properly positioned, then carefully insert the Adjustor Assembly into the base. Turn the assembly clockwise until base nut is flush with the Fuel Preporator II. base. Tighten the Base Nut. NOTE: One set of o-rings for the barrel seal are included in the Customer Service O-ring Kit. 31 Re-adjust the output pressure by turning the Adjustor Screw counter clockwise until stops against the Base Nut. Then, turn the Adjustor Screw clockwise 3 ½ full turns or the Previous Adjustment.

32 PUREFLOW AIRDOG LIMITED WARRANTIES STATEMENT For Fuel Preporator Fuel Systems FPII-150 and FPII YEARS LIMITED EXPRESS WARRANTY IMPORTANT NOTICE To activate your Warranty, you must complete and mail your Warranty Registration Card to with a copy of your Sales Receipt within 30 days of purchase. Failure to complete and submit your warranty registration card will result in a warranty period of the covered product to one (1) year from the date of purchase. (hereafter collectively, SELLER ) warrants and guarantees only to the Original Purchaser (hereafter collectively, BUYER ) that all above listed Systems (hereafter collectively, PRODUCT ) shall be free of defects of material and workmanship in the manufacturing process for the herein defined 2 Years Limited Express Warranty. The 2 Years Limited Express Warranty is limited to the PRODUCT purchased by the original BUYER of the PRODUCT and limited solely to the parts contained within the PRODUCT and EXCLUDES ALL ELSE INCLUDING FILTERS AND WATER SEPARATORS. Any PRODUCT that is in question of Warranty must be returned, shipped prepaid, to. All Warranty claims are subject to approval of PureFlow AirDog. If it is determined that a Warranty claim exists, 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. Repairs or replacements are warranted for only the remainder of the original warranty period and only to the original BUYER. Under no circumstances will the SELLER be liable for any labor charged or travel time incurred in the diagnosis for defects, removal, or re-installation of the PRODUCT, or any contingent expense. Under no circumstances will the SELLER be liable for any damage or expense incurred by reason of the use or sale of the PRODUCT. Other than expressly set forth herein, the SELLER shall in no way be responsible for the proper or improper use and service of the PRODUCT. In no event shall the SELLER be liable for any special, incidental, indirect, consequential damages of any kind or nature, whether or not the BUYER of the PRODUCT was advised of the possibility of damage or harm, arising or resulting from the use or performance of the PRODUCT and BUYER hereby waives the right to any and all such claims. BUYER, acknowledges that he/she is not relying on SELLER S skill or judgment to select or furnish goods to suitable for any particular purpose and that SELLER has no liability that will extend beyond the scope of the LIMITED EXPRESS WARRANTY contained herein, and BUYER hereby waives all remedies or liabilities, expressed or implied, arising by operation of law or otherwise (including, without limitations, any obligation of SELLER with respect to fitness for any particular purpose; merchantability; and special, incidental, indirect, or consequential damages) or whether or not occasioned by SELLER s negligence. SELLER disclaims any warranty and expressly disclaims any liability for personal injury or damages related to BUYER S use of the PRODUCT. BUYER acknowledges and agrees that the disclaimer of any liability for personal injury is a material term for the agreement and BUYER agrees to indemnify SELLER and hold SELLER harmless from any claim related to the PRODUCT and its use or performance. Under no circumstances will SELLER be liable for any damages, liabilities, costs or expenses incurred as a result of or by reason of use, performance, or sale of the PRODUCT, including without limitation, any damages, liabilities, cost or expenses incurred by reason of BUYER S negligence related to those uses of the PRODUCT. The proper installation of the PRODUCT is the sole responsibility of the BUYER. The SELLER assumes no liability regarding improper installation or misapplication of the PRODUCT. 32

33 SELLER hereby provides the following limited warranty as to the description, quality, merchantability, fitness of the PRODUCT S purpose, productiveness, or any other matter of SELLER S PRODUCT sold herewith. The SELLER shall be in no way responsible for the open use and service of the PRODUCT and the BUYER hereby waives all rights other than those expressly written herein. This Warranty shall not be extended or varied except by a written instrument signed by both the SELLER and BUYER. IN THE EVENT THAT THE BUYER DOES NOT AGREE WITH THIS AGREEMENT, THE BUYER MAY PROMPTLY RETURN THE PRODUCT, IN A NEW AND UNUSED CONDITION, WITH A DATED PROOF OF PURCHASE, TO THE PLACE OF PURCHASE WITHIN THIRTY (30) DAYS FROM THE DATE OF PURCHASE FOR A FULL REFUND. THE BUYER AGREES THAT THE INSTALLATION OF THIS PRODUCT CONFIRMS THE BUYER HAS READ AND UNDERSTANDS THIS AGREEMENT AND ACCEPTS THE TERMS AND CONDITIONS OF THIS AGREEMENT. Warranty Procedure In the unlikely event a warranty appears as if it may be warranted, the following steps are taken: 1 The customer discussed the symptoms of the problem with a PureFlow AirDog Technician. The customer is to have the system Serial Number and Model Number available for the Technician when the call is made. This will expedite all steps of the process. 2 The customer performs any and all tests requested by the PureFlow AirDog Technician. This is done to isolate the potential problem while eliminating potential installation or maintenance related issues, 3 If the PureFlow AirDog Technician determines based on the customer feedback concerning the requested testing that system may be at fault, the customer is advised that all returned pumps are tested upon arrival and should this returned pump perform at design criteria upon arrival, the customer will be charged a $50.00 fee. 4 The PureFlow AirDog Technician will first request the customer s phone number in the event the phone call is accidentally disconnected and then transfer the customer to a PureFlow AirDog Customer Service Representative. Should a Customer Service Representative not be available, the Technician will offer the Customer the option to hold, call back, or receive a return call. 5 The PureFlow AirDog Customer Service Representative will check to determine if the customer s Warranty Registration Card is on file. a. If no Warranty Registration is found, the customer will be required to supply the original purchase receipt showing the purchase date. b. If no Warranty Registration is found, the customer will be advised of the options should the system in question is out of the default warranty period (1 year). 6 The PureFlow AirDog Customer Service Representative will request the customer information, including: Name, Address, Phone Number, Model Number, Serial Number, Year / Make / Model of vehicle, Name of Dealer purchased from, Purchase Date, Description of Problem, Customers understanding of the resolution, and customer credit card information. 7 PureFlow AirDog will cover Ground Shipping charges to ship the replacement unit and will include a prepaid shipping label for the return of the defective unit. Any additional items ordered at the time of the replacement shipment will include their portion of the shipping cost. 8 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 $ against the customer s credit card as the purchase cost of the defective unit. 33

34 NOTES 34

35 NOTES 35

36 NOTES Bulletin No Printed 2011 Revised June 1,