!

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

INSTALLATION MANUAL for

The Original Fuel Air Separation System

Kit No. A6HSDE640

PLEASE READ THESE INSTRUCTIONS

THOROUGHLY BEFORE BEGINNING

INSTALLATION

CUMMINS® N-14 ENGINES

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!

Hi Pressure Fuel Air Separator

Champ

Fuel Preporator® Technology Inside 10 YEAR Limited Express Warranty

Model No. HPAS-585 Kit No. A6HSCU610

2

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)'0$+$6."7$&"8.9*&*+$'("":$+;")&$<*&="7$&">$0%;*&2.")'&+5"

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The new AirDog® Champ Final Filter Air Separator delivers all of the benefits of the original Fuel Preporator® and the AirDog® Fuel Air Separation System!

K No Fuel Pump K"LLLMMM"""NNN...***&&&"""111$$$<<<$$$+++...444"""BBBOOO999&&&...000000""":::***&&&&&&***(((+++==="K No Electrics K"

Amazing Simple Installation Mounts on frame, connects between the engine transfer (fuel) pump and engine. Air/Vapor return line connects to engine fuel return line.

Amazing Simple Operation Operates in conjunction with the engine fuel flow. Separates and removes entrained air plus vapor from fuel pump cavitation and fuel line pressure drop before the fuel enters the engine!

Hi Pressure Fuel Air Separator THE RIGHT CHOICE FOR YOUR DIESEL ENGINE!

Champ

Shipping weight 9 Lbs.

3

PureFlow® Technologies, Inc. AirDog Champ CUMMINS N-14 Section 1 Table of Contents

Section 2: Installation & Safety Guidelines

TABLE OF CONTENTS Section 1……..….….…...........……...............….....…….....Table of Contents

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

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

Section 4……..……...…..……….….…….…….….………...System Overview

AirDog® CHAMP INSTALLATION SIMPLIFIED (For Experienced Diesel Technicians)

Section 5…………………………………….….….Simplified Installation Steps

INSTALLATION PROCEDURES DETAILED

Section 6…....….............................................Mounting the AirDog® Champ

Fuel Lines and Fittings

Section 7A……..…...……….............From AirDog® Champ To Engine Head

Section 7B….….….......…..............From Transfer Pump to AirDog® Champ

Section 7C…..…….....…….....………………………Air Vapor Return to Tank

Maintenance Section 8...….….....…..............…..……..…Filter Service Recommendations

INSTALLATION GUIDELINES The installation of your AirDog® Champ can be made relatively easy by following the steps outlined in this manual, and: 1. Inventory the package components. Notify PUREFLOW® Technologies, immediately of any parts missing or damaged. 2. Read the installation manual completely. Understand how the system operates

and the installation recommendations before beginning. 3. Proper location of the AirDog® Champ 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.

4

PureFlow® Technologies, Inc. AirDog Champ CUMMINS N-14 Section 2 Installation & Safety Guidelines

SAFETY GUIDELINES! CAUTION: Chock the vehicle’s tires to prevent rolling. 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 !” of the

frame rail flange on the side of the frame rail. CAUTION: Route the fuel lines keeping them away from hot exhaust

components and/or moving parts. Properly secure the fuel lines and to prevent chaffing.

If you are uncertain of any installation procedure, contact:

PureFlow® Technologies, Inc 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.

SECTION 3: Installation Parts List

QTY DESCRIPTION Part Number IMAGE

1 Installation Manual 206-6-0610

1

AirDog® Champ High Pressure Air Separator

HPAS-585

2

Mounting Bracket Note: Unit is shipped with brackets attached.

002-3C-0003 002-3C-0004

1 Set 4 Socket Head Cap Screws, 1/4-20 x 2" Lg. 4 Lock Washers, 1/4” 4 Hex Nuts, 1/4-20

1L-A-32C 1R-6-AC 1S-1-AC

1 Set Hardware Kit, Includes: 4ea 3/8” x 1-1/2” Hex Head Bolt, 4ea 3/8” Nut 4ea 3/8” Lock Washer

1J-1-C20S 1S-1CZ

1R-6-CSZ

2 #8 - JIC Flare x !” ORB Fitting 4A-1-02-08-08-S 1 #6 - JIC Flare x 9/16-18 ORB Return Fitting 4A-1-01-06-06-S

Fuel Line Fittings 1 #6 - JIC Flare x " NPT Air/Vapor Return

Fitting 4A-1-01-A-C-SZ

1 #8 - Female Swivel x #8 Male Flare x "” Side 4A-1-11-08-08-4P

5

Champ

AirDog® Champ

TYPICAL Cummins® N-14 INSTALLATION

LAYOUT

Fuel to Engine

Engine Fuel Pump

Air/Vapor Return Line Connects to engine return line.

Engine Fuel Return To Tank

Fuel Supply Line From Tank

SECTION 4: SYSTEM OVERVIEW

Welcome to the “AirDog® Champ” High Pressure Fuel Air Separation System for Class 8 Trucks

The AirDog®, Champ with ADVANCED FUEL AIR SEPARATION is a premium fuel air separator for the Cummins® N-14 Engine.

The AirDog® Champ is installed between the engine transfer pump and the engine fuel rail, to remove virtually all entrained air and vapor from the fuel flow to the engine.

Figure 1

IMPORTANT: The AirDog® requires only one small return line connected to the low pressure side of the engine return line, for quick and easy installations.

6

PureFlow® Technologies, Inc. AirDog® Champ Cummins® N-14 Section 5.…………………………………………. Simplified Installation Steps

Simplified Installation Steps For Experienced Diesel Technicians

A.

B.

C.

Reconnect fuel line to engine here.

Connect Pressure Gauge Here! RPM GPH Fuel Rail Pressure

1,200 74.25 130-160 2,100 92.8 150-180

Step 1. Mount the AirDog® Champ on the truck frame, engine, or firewall, as space permits.

Step 2. Install fittings A. “Fuel In”, B. “Air Return” and C. “Fuel Out”.

Step 3. Disconnect the #8 fuel line from the engine transfer pump. Reconnect the fuel line to the Champ “Fuel Out” fitting (Step. C. above).

Step 4. Measure, cut, and assemble a new #8 fuel line to connect the transfer pump outlet port to the Champ “Fuel In” port.

Step 5. Disconnect the engine fuel return line from the #8 JIC flare fitting located on the side of the engine.

Step 6. Assemble and install the #8 return “T” on the #8 JIC. Step 7. Reconnect the engine fuel return line to the return “T”. Step 8. Measure, cut, and assemble a #6 Air/Vapor return line and connect the Champ Air/Vapor return port to the Return “T” just installed. Step 9. Be sure to check the fuel rail pressure. Reset if necessary!

Disconnect fuel line to Engine from here.

7

PureFlow® Technologies, Inc. AirDog® Champ Cummins® N-14 Section 6 Mounting the AirDog® Champ

MOUNTING THE AirDog® Champ ON THE TRUCK’S FRAME!

Selecting the Best Location to Mount The AirDog® Champ !

Installing the AirDog® Champ 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 secondary fuel filter and back of engine head."

• Protection from the elements and road debris."• Accessibility for service."

"#$%&'(!)!*+,!-!depicts the AirDog® Champ mounted on the frame.!/0'&'!*&'!1*+2!3*&#*4#5+(!#+!40'!*&&*+$'1'+4(!56!40'!75185+'+4(!5+!40'!3*&#5%(!4&%79(.!:#40!*! ;#44;'! #+$'+%#42<! 40'!AirDog® Champ! 7*+! ='! '*(#;2! #+(4*;;',! 5+! *+2! >;*((! ?!/&%79.!

! Figure 2! Figure 3 !

6-1. Hold the AirDog® Champ, with the brackets and filter 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 4 Figure 5 6-2. Mark and center punch the hole locations. Drill a 3/8” hole at each of the 4

locations and attach the AirDog® Champ brackets WARNING! DO NOT DRILL INTO OR DAMAGE ANY WIRING, AIR LINES OR OTHER COMPONENTS LOCATED BEHIND THE FRAME RAIL.

8

PureFlow® Technologies, Inc. AirDog® Champ Cummins® N-14 Section 6 Mounting the AirDog® Champ

MOUNTING THE AirDog® Champ ON THE TRUCK’S FRAME!

Cont’d 6-3. In this installation, the spring shackle bracket is in the way. Using PureFlow Technologies Universal Mounting Bracket & spacers easily overcomes this obstacle! Figure 6

Figure 7 @AB.! C*&9!*+,!7'+4'&!8%+70!40'!(';'74',!05;'!;57*4#5+(.!D&#;;!40'!05;'(!*+,!*44*70!40'!

%+#3'&(*;!15%+4#+$!=&*79'4.!E44*70!40'!E#&D5$F!>0*18!=&*79'4(!45!40'!GH+#3'&(*;!I&*79'4J.!!

Figure 8

9

PureFlow® Technologies, Inc. AirDog® Champ Cummins N-14 Section 7 Fuel Lines & Fittings

A. C. B.

Route fuel line from here to here!

Reconnect fuel line to engine here.

7

INSTALLING THE FUEL LINES AND FITTINGS

Fuel Supply Line: The fuel supply lines from the transfer pump to the AirDog® Champ and to the engine should be size 8.

Air/Vapor Return Line: The AirDog® Champ return line should be connected to the engine’s return line, low pressure side. A size 6 line for the Air/Vapor return line is adequate.

7A-1. Install fittings A. “Fuel In”, B. “Air Return” and C. “Fuel Out”, in the AirDog® Champ.

Figure 9!! !

Fuel Line From AirDog® Champ to Engine

7A-2. Disconnect the #8 fuel line from the engine transfer pump (Fig. 10). Re-route the fuel line and connect it to the Champ, “Fuel Out” to Engine, port “C”, it may be necessary to make a new fuel line.

Figure 10 Figure 11

Fuel Line From Transfer Pump to AirDog® Champ 7B-1. Measure, cut, and assemble a NEW #8 fuel line, as necessary, to connect the engine transfer (fuel Pump) to the AirDog® Champ.

Figure 12 Figure 13 7B-2. Connect the new #8 fuel line to the fuel transfer pump and to the AirDog® Champ “Fuel In” port.

Disconnect fuel line to Engine from here.

10

PureFlow® Technologies, Inc. AirDog® Champ Cummins® N-14 Section 7 Fuel Lines and Fittings

Route fuel line from here to here!

Connect Pressure Gauge Here!

RPM GPH Fuel Rail Pressure 1,200 74.25 130-160 2,100 92.8 150-180

Section 7C: Air Vapor Return to Tank

7C-1. Disconnect the ENGINE fuel return line from the #8 JIC fitting on the side of the engine. Figure 15

Figure 14 Figure 16 7C-2. Assemble the AirDog® Champ Special Return “T”, Fig. 15, and install it on the engine fuel return fitting. Reconnect the engine return line to the return “T”.

Figure 17 Figure 18 7C-3. Measure, cut, and assemble a #6 Air/Vapor return line and connect the Champ Air/Vapor return port to the Special Return “T” just installed.

Be sure to check the fuel rail pressure. Adjust as necessary!

11

PureFlow® Technologies, Inc. AirDog® Champ Cummins® N-14 Section 8 Fuel Lines and Fittings

Built in Check Valve Prevents fuel from

draining from the engine head during filter changes.

Servicing the AirDog® Champ Fuel Filter

It is recommended to replace the fuel filter at 25,000 miles of service or every other engine filter service.

When replacing the fuel filter, be sure to clean the under side of the AirDog® Champ base. Follow the instructions on the filter for proper tightening procedures.

Figure 19 Dispose of waste fuel and used filters properly to protect OUR environment!

AirDog® Champ Fuel Filter

6 Micron Micro Glass

12

Copyright © 2014 Bulletin No. 206-6-0610

CD Patents, LLC Revised November, 2014 All Rights Reserved