INDUSTRIAL Fuel Air Separation System INSTALLATION MANUAL For Trucks Equipped with the VOLVO VED-12 & D13 ENGINES PLEASE READ THESE INSTRUCTIONS THOROUGHLY BEFORE BEGINNING INSTALLATION Kit No. A3SPBT406 NOW WITH DEMAND FLOW Revised 2/24/17 Proudly Made in the USA www.pureflowtechnologies.com 1-573-635-0555 or 1-877-463-4373 Providing Test Cell Performance in Real World Conditions Since 1993! PROTECTED UNDER THE FOLLOWING PATENTS CANADA UNITED STATES OF AMERICA MEXICO 2,108,391 5,355,860; 5,746,184; 6,729,310 270409 NEW ZEALAND ITALY AUSTRALIA HONG KONG ECUADOR 532356 1362177 2005101054 1061420 PL10-2021 Additional Foreign Patents Issued and Pending in Europe, South America, Japan, and China!
INDUSTRIAL Fuel Air Separation System THE RIGHT CHOICE FOR YOUR DIESEL ENGINE! New Design 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! Bearings Quick Change Motor If necessary, the motor can be removed and replaced in a matter of minutes. Low Fuel Pressure Switch and LED Indicator Lets you know when to service the fuel filter and water separator before suffering power loss. NO MORE GUESSING! New LoveJoy Coupler System The LoveJoy Coupler System is self-aligning and eliminates virtually all vibrations. Positive Air Separation with primary air discharge port. Dual Port Pump Balances the gerotor for quiet operation and higher flows. Demand Flow System Easy installation, only one small line connected to the engine return line to return air/vapor to the tank. Protective Wire Screen In water separator nipple. Adjustable Regulator For just the right fuel pressure. 6 Micron Particulate Filters Long Lasting MicroGlass Media Water Separator/Prefilter Long Lasting Wire Mesh Media CARB Executive orders No. D-595-1 & D-595U-1, permit the advertisement, sales, and installation in California of AirDog, AirDog II, Fuel Preporator, and Fuel Preporator II s FPII-150 & FPII-200 8¼ W x 3 7/8 D x 12¾ T s FPII-125 7 W x 3 D x 10 T s 2
SYSTEM OVERVIEW Welcome to the AirDog Fuel Preporator Fuel Air Separation System for Class 8 Trucks The AirDog, with ADVANCED FUEL AIR SEPARATION, DEMAND FLOW, ADJUSTABLE REGULATOR, LOW PRESSURE SWITCH with LED INDICATOR and the NEW 4G-HD FUEL PUMP, is a premium fuel filtration and delivery system for the Volvo VED-12 & D13 Diesel Engine. 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 AirDog can now perform as designed, delivering test cell performance while in real world use! The AirDog removes water, particulates and most importantly, the air that becomes entrained in diesel fuel, from the fuel flow to your engine. The entrained air and vapor that is 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. All AirDog products are manufactured with a personal touch, unsurpassed attention to detail and the most stringent quality assurance! Excess Fuel From Injectors TYPICAL INSTALLATION LAYOUT Fuel Exchange Fuel Line to Transfer Pump Air/Vapor Return Line Pure Fuel to Engine at Positive Pressure Fuel Supply Line Entrained Air in Fuel from Agitation & Sloshing Fuel Preporator Figure 1 The AirDog requires only one small return line connected to the engine return line, for quick and easy installations. 3
Section 1 TABLE OF CONTENTS 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 On the Truck Fuel Lines, Fittings & Low Fuel Pressure Sensor Switch Section 6...Fuel Fittings & Sensor Switch Section 7A.......AirDog Air/Vapor Return Line Section 7B........Fuel Line from AirDog to Engine Section 7C.............From Tank to AirDog Electrical Harness Section 8.................Electrical Harness Section 9................... Initial Start Up Maintenance Section 10........... Filter Service Recommendations Section 11....Pressure Regulator 4
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, 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 fittings 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 flange 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 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 as found on your truck. 5
Section 3 QTY Description Part Number Image 1 Installation Manual 206-1-0406 1 AirDog FPII-150 1 Wiring Harness with Indicator Light 5E-2-010 1 Fuel Filter Monitor Light Plate 201-3-0004-S 1 Fuel Pressure Sensor (5 psi) 5C-9-007 1 7 ft. Section DOT Air/Vapor Return Line 4C-1-02-05-010 1 Sandwich Mounting Bracket Kit for AirDog & Champ 002-3C-0010-SBF Includes: 1 Front & 1 Back 002-3C-0011-SBB Center Bracket 002-3C-0006PCB 2 Mounting Bracket 002-3C-0003 002-3C-0004 908-01-0406 Installation Hardware Kit 901-08-0100-SB 1 Hardware Kit, Includes: 3 ea 3/8-16 x 3-1/2 Hex Head Bolt 1J-1-C56SZ 7 ea 3/8 Nut 1S-1-CSZ 7 ea 3/8 Lock Washer 1R-6-CSZ 4 Screw, 3/8-16x1 F/H SHCS 1M-C16SZ 901-08-0100 6x6 Bag - Down to 3x3 1 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 Socket Head Cap Screws, 1/4-20 x 2 Lg 1L-A32C 4 Lock Washers, 1/4 1R-6-AC 4 Hex Nuts, 1/4-20 1S-1-AC 908-08-0800 AirDog Standard Fitting Kit 2 #10 Straight JIC Flare x 1/2 NPT Fitting 4A-1-01-10-08-S 2 #10-90 Swivel x JIC Flare Fitting 4A-2-04-10-10-S 1 #6 JIC Flare x 1/4 NPT Air/Vapor Return Fitting 4A-1-01-A-C-SZ 1 Grommet 5J-1-1-04-2758 908-01-0406-IFK Return Line Fitting Kit 1 16 mm Male ORB x 16 mm Female ORB x 908-09-0100-M #6 JIC Air/Vapor Return Fitting (Available only from PureFlow Technologies) 2 # 6 JIC Female Swivel x 3/8 Pushlock Hose Barb 4A-1-09-06-06-SZ 1 #6 Swivel x #6 JIC Forged 90 4A-2-04-06-06-S 1 1/2 NPT T 4A-4-01-08-08-08 1 1/2 Male NPT x 1/2 Female NPT x 2 90 Elbow 4A-2-09-08-08 1 3/4 Hose Barb Coupler 4A-1-16-12-12 Parts List 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 mounting brackets, mounting hardware, wiring harness and basic fuel fittings. 6
Section 4 Selecting the Best Mounting Location 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 filter 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! The Volvo primary fuel filter is usually found on earlier model trucks mounted on the passenger side frame rail, just to the rear of the bumper brackets. Additionally, Volvo uses plastic type fuel lines and plastic quick connect fittings. Figure 2 Figure 3 The AirDog can be easily mounted in the same location as the OE primary fuel filter in this application, as shown in Figure 3. Figure 4 On later model Volvo trucks, such as this 2006 (fig. 4), the primary filter may be found on the driver s side. Figure 5 Figure 5 shows the AirDog mounted on the original filter bracket. The bracket was reversed to do this. See Universal Sandwich Mounting Bracket Guide on Next Page 7
Section 4 Selecting the Best Mounting Location NO DRILL Universal Sandwich Mounting Bracket Now included with all engine specific AirDog FPII Kits!! 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. Sandwich bracket slides right over existing frame. 8
AirDog FPII-150 Section 5 Mounting the AirDog MOUNTING THE AirDog ON THE TRUCK S FRAME! At the Original Primary Filter Location Remove the Original Fuel Filter 5-1. Disconnect the fuel line from the fittings in the filter housing. Figure 6 5-2. Should the fuel lines utilize the plastic quick connect fittings shown in Figure 6. Remove the Quick Connect fittings from the original fuel filter housing. Note: Save these fittings, they will be needed later to connect the plastic fuel lines to the AirDog Figure 7 5-3. Disconnect the coolant lines from the fuel heater portion of the filter assembly. 5-4. Connect the coolant lines together with a hose barb coupler. Fuel Heater Lines Secure with original hose clamps (Fig. 8). Figure 8 Figure 9 5-5. Remove the original primary filter assembly from the frame. 5-6. Hold the AirDog, with the brackets and filters attached, next to the frame at the selected mounting location. Check for clearance. Figure 10 9
AirDog FPII-150 Section 5 Mounting the AirDog Mounting the AirDog on the truck s frame! 5-7. Mark and center punch each hole location. 5-8. Drill a 3/8 hole at each of the 4 previously marked locations. WARNING! DO NOT DRILL INTO OR DAMAGE ANY WIRING, AIR LINES OR OTHER COMPONENTS LOCATED BEHIND THE FRAME RAIL. Figure 11 Figure 12 Figure 13 5-9. Loosely assemble the mounting brackets to frame. Loosely assemble the AirDog on brackets. Now, snug the fasteners to achieve a good relaxed fit and then properly torque all the fasteners. NOTE: These steps are necessary to prevent stress cracks from forming in the mounting brackets due to vibration The example below shows the AirDog installed on a later model Volvo. 5-10. When mounting the AirDog on later model Volvos, remove the original filter and then reverse the mounting bracket. Figure 14 Figure 15 5-11. Mount the AirDog on the original filter bracket. It may be necessary to fabricate an adaptor bracket. Note: Contact PureFlow Technologies for optional adaptor brackets. Assembly Instruction for Hose Barb 1. Cut hose line to length. 2. Apply oil to fitting. 3. Push fitting into line until seated. 10
Section 6 Pressure Sensor Switch and Fuel Fittings Pressure Sensor & Fuel Fittings IMPORTANT: Use diesel compatible thread sealer when installing NPT fittings. 6-1. Remove the 1/8 NPT plug located in the end of the 45 elbow. Install the pressure sensor switch into the elbow. Figure 16 Figure 17 6-2. Install the #6 JIC x ¼ NPT Air/Vapor return fitting in the AirDog port marked TANK. 6-3. Install the Quick connect x ½ NPT fitting removed from the original primary filter in the port marked ENGINE. Figure 19 Figure 18 6-4. If your installation places the AirDog on the passenger side as seen in Fig. 13, use the 90º ½ Male NPT x ½ Female NPT fitting and the Quick Connect x ½ NPT fitting to connect the fuel supply line. FUEL LINE OVERVIEW The AirDog 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 plastic or 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 will allow the use of the original fuel lines and fittings. Fuel Supply Line: The fuel supply lines from the tank to the AirDog and to the engine should be size 10 or, at the absolute minimum, size 8 (1/2 ID). Air/Vapor Return Line: The AirDog Air/Vapor return line can be connected to the engine s return line. A size 6 is adequate for the Air/Vapor return line. Primary Fuel Filters: It is most important that there are no fuel filters between the fuel tank and the AirDog or between the AirDog and the engine s transfer pump to plug and cause restriction. These filters should be removed from the system as part of the AirDog installation. Secondary Fuel Filters: DO NOT REMOVE SECONDARY FUEL FILTERS. This is the filter between the transfer pump and the engine. 11
Section 7 Fuel Lines Section 7A: Installing the AirDog Air/Vapor Return Line. The AirDog, with DEMAND FLOW, returns entrained air & vapor (foam) with very little fuel to the tank. With these features, the AirDog air/vapor return line can be connected directly to the engine return line. NOTE: For your convenience, 7 feet of #6 line and fittings are included. 7A-1. In the example depicted in figure 20, install the 16mm AirDog return T & O ring on the fuel return line. Attach the Quick Connect 16mm female fitting to the return fitting. Re-attach the original fuel return line. Figure 21 Figure 20 7A-2. Measure and cut the length of #6 fuel line required to connect the AirDog Air/Vapor return port (A) to the new return T (B) installed on the secondary fuel filter head. Assemble and install the fuel line per standard procedures, connecting it to the relative fuel fittings. For Trucks with only one fuel tank, it may be easier to run the Air/Vapor Return Line directly to the tank. CAUTION: Do not connect the AirDog return line to one tank on a two tank system! 7A-3. Remove the plug from an extra port. In some cases, it may be necessary to drill and tap a port. Figure 22 Figure 23 7A-4. Install the NPT x #6 JIC Flare fitting into the port. 12 Figure 24
Section 7 Section 7A: Connecting the AirDog Air/Vapor Return Line to the Tank, Cont d! Fuel Lines 7A-5. Measure and cut a length of fuel line required, when properly routed, to connect the AirDog Return Line to the new fitting in the fuel tank. Figure 25 AirDog Air/Vapor Return Port Figure 26 7A-6. Assemble the fuel line per standard procedures. 7A-7. Connect one end of the Air/Vapor return line to the Return Port fitting on the AirDog. Figure 27 Figure 28 7A-8. Route and connect the other end of the Air/Vapor return line to the return fitting on the fuel tank. Properly tighten both fittings. OR Section 7B: Fuel Line from Fuel Preporator to Engine Note: AirDog Mounted at Original Filter Position! 7B. Re-connect the original fuel line to the engine to the AirDog out to ENGINE port. Be sure the Quick Connect fitting clicks to secure the fuel line. Figure 29 Figure 30 Figure 31 NOTE: Figure 31 shows the connection at the engine (filter head). 13
Section 7 Fuel Lines Section 7C: Fuel Line from Fuel Tank to the AirDog 7C. Re-connect the original fuel supply line to the AirDog fuel inlet port. IMPORTANT: Be sure the Quick Connect fitting clicks when connecting the fuel line. Figure 32 Figure 33 NOTE: Figure 33 shows the connection at the engine (filter head)! ELECTRICAL HARNESS The AirDog wiring harness has a low pressure switch and an amber LED indicator light as standard equipment. VERY IMPORTANT: The LED Indicator Light will remain off. Should pressure flow to the engine drop below minimum requirements, the light will immediately illuminate. First check the water separator. Then, check the screen in the water separator nipple. Clean or replace as necessary. THE AIRDOG, WIRING HARNESS. AirDog Pump Motor Lead Pressure Sensor/Switch Lead Indicator Light & Lead Battery Positive Lead Battery Negative Lead Figure 34 Relay Lead Securing the Relay to the Vehicle 8-1. Secure the Relay to the vehicle. This picture shows the Relay mounted on the firewall. Figure 35 14
Section 8 ELECTRICAL HARNESS cont d Electrical Harness 8-2. Route the pump motor and indication light sensor lead to the AirDog. Connect the 2 pin Deutsch connector on the end of the wiring harness to the pump motor lead. Figure 36 Figure 37 8-3. Connect the lead with the green seal to the low fuel pressure sensor switch. Connecting the AirDog Relay Trigger Lead The Relay Trigger Lead must be connected to a contact point that is HOT when the starter key is in the ON or RUN position, such as a spare fuse holder in the fuse panel as shown in Figure 38, DO NOT connect the relay lead to a point that is HOT when the starter key is in the ACCES- SORY ON position. To connect the relay trigger lead to the fuse panel in the dash: 8-4. Drill a 5/8 hole in firewall to route the red, relay trigger wire with the mini fuse tap and indicator light lead through the firewall. Install the grommet around the wire loom to protect it from chaffing. The red relay trigger lead is in the same loom with the indicator light leads. Figure 38 Figure 39 8-5. Route the relay trigger lead 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. To install the fuel filter monitor light and dash plate Figure 40 8-6. Select a location on the dash that is easily visible to the driver. 15
AirDog FPII-150 Section 8 Electrical Harness Installing the Fuel Filter Monitor light and dash plate 8-7. Open or remove the dash components as necessary to access the area behind the selected location. Figure 41 Figure 42 8-8. Drill a 5/16 hole at the selected location. Be very careful when drilling. Do not damage components located behind the dash. 8-9. Install the Dash Plate and Indicator Light in the dash. 8-10. Connect the Indicator Light Lead to the connector on the wiring harness. 8-11. Re-install the removed dash components to their original position. Figure 43 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. 8-12. Route the Red & Black power supply leads to the alternator. Connect the Black (-) ground lead to the alternator Ground connection. Figure 44 Figure 45 8-13. Connect the Red (+) positive lead to the alternator Hot Lead going to the battery. 16
Section 9 Initial Startup SECTION 9: INITIAL START UP PROCEDURE The AirDog is a self priming system. However, to prevent damage to a dry seal and reduce the life expectancy of the system, it is suggested to pre-fill the water separator/pre-filter with diesel fuel to the bottom of the NUT PLATE. r 9-1. Pre-fill the water separator/pre-filter with diesel fuel up to the bottom of the nut plate. r 9-2. Turn the starter key to the on/run position. r 9-3. The AirDog 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 LEAKS. BE SURE ALL LINES ARE PROPERLY SECURED TO PROTECT FROM CHAFFING AND ABRASION. RECHECK ALL ELECTRICAL LINES, SECURE AS NECESSARY. r 9-4. Start your engine! VERY IMPORTANT: Should pressure flow to the engine drop below minimum requirements, the AMBER LED light will immediately illuminate. First check the water separator. Then, check the screen in the water separator nipple. Clean or replace as necessary. 17
Section 10 Fuel Filter & Pre-Filter Servicing the AirDog Fuel Filter and Water Separator/Prefilter The AirDog low pressure switch monitors the fuel filter and water separator! FUEL FILTER: Plugging of the fuel filter will cause the AirDog Indicator Light to illuminate. Replace the fuel filter as necessary! Typically our fuel filters are good for a 40,000 mile service period because they are micro glass media instead of typical paper. It is recommended to replace the fuel filter at 40,000 miles of service OR when the AMBER Indicator Light illuminates, which ever comes first! When replacing the fuel filter, be sure to clean the under side of the AirDog base. 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. AirDog Fuel Filter Pre-filter Nipple with Wire Screen (1 1/8th Inch Hex) Figure 46 Prefilter/Water Separator With Drain Valve The Water Separator/Pre-filter WATER SEPARATOR: Should the water separator/pre-filter or the wire screen in the nipple become plugged, preventing sufficient operating pressure flow to the engine, the Amber Indicator Light will immediately illuminate Check the water separator/pre-filter for plugging. Clean or Replace as necessary! If the light continues to be on, check the screen in the water separator/pre-filter nipple for debris and plugging. Clean as necessary! 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. Before re-installing the water separator after cleaning, be sure to clean the under side of the AirDog base. Follow the instructions printed on the water separator/pre-filter for proper tightening procedures. DO NOT over tighten and damage the water separator with a filter wrench. Caution: Be careful to prevent any contaminates or debris from entering the water separator when 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. Dispose of waste fuel and used filters properly to protect OUR environment! 18
Section 11 How to Remove and Re-install the Pressure Regulator! Pressure Regulator The Adjustable Pressure Regulator is made of all stainless steel components, except for the viton O rings. Regulator Components A - Adjustor Screw B - Jam Nut C - Base Nut D - Spring E - Plunger F - Plunger O ring Figure 47 STEP 1 STEP 2 STEP 3 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 AirDog 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 Tighten the Base Nut. Re-adjust the output pressure Spring are properly positioned, by turning the Adjustor Screw then carefully insert the Adjustor counter clockwise until it stops Assembly into the base. Turn the against the Base Nut. assembly clockwise until the base nut is flush with the surface of the AirDog base. NOTE: Units built before December 1, 2013 require 5 turns for the correct output pressure. 19
Copyright 2016 CD Patents, LLC All Rights Reserved 20 Bulletin No. 206-1-0801 Revised February, 2017