AIR DOG - Xtreme Diesel Performance

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INSTALLATION MANUAL





MODEL FP
-
100

WITH OPTIONAL LOW PRESSURE WARNING LIGHT



DURAMAX TRUCKS






READ INSTRUCTIONS THOROUGHLY

BEFORE BEGINNING INSTALLATION.












PUREFLOW® TECHNOLOGIES, INC.

5400 BUSINESS 50 WEST

SUITE 8










(573) 635
-
0555 VOICE


2

JEFFERSON CITY, MO 65109






(573) 635
-
0778 FAX


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 step
s outlined in this manual.


1. Inventory the package components completely. Notify
PUREFLOW®

TECHNOLOGIES, INC.

Immediately of any parts missing or
damaged.


2. Read the owner’s manual and the installation manual completely.
Understand how the system opera
tes and installation
recommendations before beginning installation.


3. The installation recommendations contained herein are suggested
installation guidelines only. Individual installations may vary.


Use good judgment and common sense when installing the

AirDog™


If any installation procedure is uncertain, contact
PUREFLOW®
TECHNOLOGIES, INC

for technical assistance.


Please fill out and mail the Product Registration/Warranty Card
enclosed with this manual.


3

Installation Manual







PUREFLOW® DIESEL SY
STEM

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 of Electrical H
arness

Section 7

................................
...........

Final Check List




4

Installation Manual










Section 1

PUREFLOW® DIESEL SYSTEM

AirDog




OVERVIEW


The PUREFLOW® DIESEL SYSTEM AirDog™ Air/Fuel Separation System is the “missing link”
between the fuel tank and the engine for die
sel 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 LB7 & LLY engines.
Connecting the AirDog™ to the stock 3 /8"
OD

(outside diameter) fuel suction tube at the tank is
OK.



Satisfactory performance and operation from the AirDog™ depends upon proper
installation and maintena
nce.



TYPICAL INSTALLATION





5

Installation Manual










Section 2

PUREFLOW® DIESEL SYSTEM

AirDog



AirDog™ PARTS LIST



Qty

Description




Part Number



Image


1

AirDog™













1

Mounting Bracket








1

Installation Manual









Optional Indicator Light Assembly





Includes: Indicator Light, Dash


Plate, Grommet & Pressure Switch



1

Electrical Harness







1

Mounting Hdwr Kit, Unit
-
to
-
Bracket




Includes: 4 Il
-
A20C Socket Head Cap Screws, 1/4
-
20 x 1
-
1/4" Lg. Stainless S
teel




3 1J
-
1
-
C20SN Bolt, Hex Hd., Grade 8, 3/8
-
16 x 1
-
1/4" Lg.




4 1S
-
1
-
ASN Hex Nut, 1/4
-
20, Stainless Steel




3 1S
-
1
-
CSN Hex Nut 3/8
-
16 Steel, Nickel Plated




4 1R
-
6
-
ASN Washer, Split
-
Lock, Helical, #1/4, Stainless Steel




3 1R
-
6
-
CSN Washer, Sp
lit
-
Lock, Helical, #3/8, Steel, Nickel Plated



2

Fuel Fitting, #8 SAE male to 3/8"
-
NPT

4A
-
1
-
01
-
08
-
06
-
B





6

NOTE: Various components and materials discussed in this manual that are marked


"(*)" are special to a particular vehicle installation and sup
plied in a separate kit.


7

Installation Manual










Section 3

PUREFLOW® DIESEL SYSTEM

AirDog





Duramax Truck Installation Accessory Kit Includes


Straight #8 flare to ½” hose barb pushlock





3

90 #8 swivel female to ½” hose barb pushlock




1

90 #8 swivel female to #8 male flare






1

½” Dorman pushlock to ½” hose barb pushlock assy.



2

Hos
e Clamps









2

2” filler/return tube









1

Hose











17ft.

Frame bracket, backup plate, 3/8
-
16x4 ½” HHCS




3

3/8” flat washers, 3/8
-
16 lock nut






3

12” Cable Ties









5

6” Cable Ties









10

¼” Insulated female spade connector






1

Mini fuse tap









1



SAFETY GUIDELINES AND WARNINGS!



IMPORTANT

Use diesel fuel compatible thread sealer on all NPT tapered pipe
thread fuel fitting connections!


IMPORTANT


When installing push lock fuel line fittings remember to




lubricate the

fittings with oil before inserting fittings into




the fuel line.


NOTE:

Proper location of the AirDog™ on the vehicle is essential.
Consider hazards presented to the equipment by road debris and
the elements.


WARNING!

Frame rails should not be drilled

into or welded upon.


CAUTION:

Wear safety glasses when operating power tools such as drills
and grinders or when using a punch or chisel.


CAUTION:

Use common sense when routing fuel lines and electrical
harnesses. Keep them away from hot exhaust compone
nts and/or
moving parts. Properly secure lines to prevent chaffing.


8

Installation Manual










Section 4

PUREFLOW® DIESEL SYSTEM

AirDog



INSTALLATION PROCEDURES


For LB7 and LLY models


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 mountin
g 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. After positioning bracket, properly torque fasteners.






STEP 1

3/8
-
16 x 4 ½ Lg.


9

Figure 1: Loc
ation of bracket may change depending on make, model and year of the truck.


Installation Manual










Section 4

PUREFLOW® DIESEL SYSTEM

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 AirDog
TM
. Adjust AirDog
TM

to its bracket using 1/4
-
20 stainless steel socket head screws provided. Attach AirDog™ and bracket to the
frame
mounting bracket

with 3/8
-
16 Hex head bolts. Secure all fastener
s, as illustrated.


STEP 2



Mount and secure AirDog™ to frame and bracket.




This is how your AirDog™ should look like after these procedures have been completed.


10

Installation Manual










Section 5

PUREFLOW® DIESEL SYSTEM

AirDog



FUEL LIN
ES


Fuel Suction Lines


5
-

1

From the driveshaft side of the fuel tank remove the factory engine supply line from the top
of the fuel tank. It may be necessary to pull down on the sheet metal shield while using a
proper size (1/2”) transmission or fuel

line disconnect tool to slide under the fuel line
connection. Disconnect factory fitting and remove the fuel line from the tank.


5
-

2

Next, remove the other end of the fuel supply line from the frame mounted line. This
connection is located between t
he fuel cooler and the front of the fuel tank. Slide the fuel
line disconnect tool under the fitting as above and remove the line. You may then remove
and discard the 18” of factory flex line or seal both ends and leave in place.


5
-

3

Install our sil
ver hex line fitting onto the end of the kit supplied ½” fuel line and push fully into
hose. Push hex fitting and hose onto the top of the fuel tank supply outlet, verify that it
clicks and locks into place. Measure the hose route to the inlet of the
AirDog and make a
square cut on the ½” fuel line at the proper length. Use the straight #8 push
-
lock flare fitting
inserted fully into the hose and assemble to the inlet on the AirDog. Torque properly. Use
the provided zip ties to secure all fuel lines.









Fig. 3 Fuel line installation






Fig. 4: Installation of fuel suction line.

Fuel

suction line

# 8 Flare Fitting

Fuel Line

To AirDog


fuel “in” port

To

fuel tank


11

Installation Manual










Section 5

PUREFLOW® DIESEL SYSTEM

AirDog



Fuel Suction Line

Cont’d



5
-

4

Connect the engine supply line from the AirDog™ to the factory line (in front of fuel tank
and behind the fuel cooler) in the same manner as the suction line, making sure the fuel line
has adequate length for a smooth r
adius at the bends. Double check that you connect to the

proper port on the AirDog. (see note below).


Note
: Do not confuse AirDog™ ports/fittings. The engine supply, pressure port is the ¾” brass
hex fitting on the AirDog™ and nearest the AirDog™ m
odel/ID plate (out board when mounting in
front of the wheel well. The larger (7/8”) silver fitting is the AirDog return line port and is
connected to the filler neck tube in the next step. If these lines are improperly routed the AirDog™
will not provi
de the designed pressure to the engine.



12

Installation Manual










Section 5

PUREFLOW® DIESEL SYSTEM

AirDog




'RETURN TO TANK' FUEL LINE


5
-

5

Installing fuel 'Return to Tank' assembly in filler tube. Install the kit supplied return line fitting

in the filler neck hose. Use a sharp knife to remove approximately 1 ½” of the rubber filler
neck connecting hose, slide the kit supplied 2” hose clamps onto each end of the filler neck.
Install the fitting into the hose but leave the clamps loose to all
ow repositioning of fitting for
the hose connection.








STEP 1.







STEP 2.

Cut filler tube as illustrated,
removing 1
½

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.






Figure 7: Installing 'Return to Tank' assembly

cut filler tube

Filler Tube

Fuel Return
Fitting

Hose Clamp

Fuel Tank

Fuel Tank

Filler Tube


13


Installation Manual










Section 5

PUREFLOW® DIESEL SYSTEM

AirDog




Return Line installation



5
-

6

Cut th
e ½” fuel line hose to proper length; connect the tank return line to the filter neck hose
with a straight push
-
lock fitting. Connect the other end to the AirDog™ using a straight
push
-
lock fitting in the hose and the kit supplied 90 degree fitting to atta
ch to the AirDog™
return port. (Again, the larger silver fitting is the return port and is marked “Tank” on top of
the AirDog™). Double check all flare fittings for proper torque and tighten as necessary.






STEP 1.


Measure and cut length of 1/2"
ID fuel
line necessary to connect AirDog™ to
Doeturn q漠qan欧 assem扬y in filler tu扥⸠
fnstall ⌸#pwivel x 봠" 灵shl潣欠fitting
int漠oach⁥n搠潦⁦ueline.


pqbm′


Connect fuel line to AirDog™ port marked
DqAkhD C ⌸#flare fitting 潮 Doeturn q漠
qan欧 fil
ler tu扥 assem扬y⸠mr潰orly t潲煵e
fittings⸠.



IMPORTANT: Properly torque all fuel fittings and connections. Use 'ties' to secure fuel
lines to vehicle to prevent chaffing and abrasion. No clamps are necessary for push
-
lock
fittings.

# 8 Flare Fitting

Return Line

Fuel suction
line

To engine

Return to
tank


14

Installation Manua
l










Section 6

PUREFLOW® DIESEL SYSTEM

AirDog



WIRING HARNESS


The
AirDog™

is equipped with a relay controlled wiring harness that connects directly to the
battery. Optional "low fuel pressure" warning light available.


6
-

1

Connect the wiring harness to the AirDog™ and route it along the left f
rame rail to the
engine compartment. Use the provided zip ties to secure the wiring harness.


6
-

2

Pull the harness into the engines compartment along the left inner fender. The red ring
terminal must connect to a battery supply, the green ring ter
minal to a clean and sheltered
ground and the black wire without a terminal end, to an ignition “hot” wire.


6
-

3

Remove the plastic housing (skirt) around the fuse box. On most models it will be
necessary to temporarily remove the fender/cowl brace

to allow the fuse box skirt
clearance.


6
-

4

After you gain access to the fuse panel, use a test light or voltmeter to find a battery terminal
that stays hot. Normally this is the stud at the inside rear of fuse box (see pics). Remove
nut and insta
ll red ring terminal onto stud and tighten nut.


6
-

5

Find a good, clean and protected ground for the green ring terminal and fasten securely to
ground. Good ground bolts are on the firewall below the hood hinge.


6
-

6

The black wire on the harne
ss is the trigger wire for the relay and must be connected to a
fused wire or terminal that will provide 12volts only when the key is in the on or run
position. We supply a fuse tap and spade connector for this, if you choose to use them.






15


Install
ation Manual










Section 6

PUREFLOW® DIESEL SYSTEM

AirDog




6
-

7

Locate the ignition fuse in the fuse box, remove the fuse and check for the terminal that is
hot when key is turned on. Push the fuse tap on the opposite fuse terminal (protected side
of the fuse) and reinstall fuse. Crimp spade connector to
the black harness wire after cutting

the wire to proper length. The trigger wiring only requires milliamps to operate the
AirDog™ so there will not be an amperage draw on the ignition fuse.


6
-

8

Tie the wires, secure with zip ties and reinstall fuse
box skirt, cover, and fender brace.


6
-

9

Optional light kit. Remove 1/8” npt plug located in top of base, below the motor. Screw in
pressure switch and tighten. Fasten the two wires from the wire harness to the pressure
switch.


6
-

10

Drill a 5/8" ho
le in firewall approximately 2 inches to the door side of the steering column to
allow entry of the Indicator Light harness into the passenger compartment.


6
-

11

Route the Indicator Light harness through the firewall. Install the grommet supplied in kit
around wiring harness where it passes through the firewall to prevent chaffing.


6
-

12

Install Indicator Light and Dash Plate in lower left dash area or
where desired
. Drill an
11/16" hole at the desired location to mount the indicator light assembly. Ins
tall the adhesive
backed dash plate by removing the backing and matching the corresponding dash plate hole
with the 11/16" hole.


6
-

13

Properly assemble the indicator light in the dash plate. Connect the two female connectors
on the wiring harness to th
e spade connectors on the indicator light.


Caution:

If these wires touch each other or a ground when the key is on it will short out the circuit
and blow the glass, inline, fuse.



6


14

The AirDog™ should now run when the key is in the on position.





BE SURE TO PROPERLY ROUTE AND SECURE THE WIRING HARNESS TO THE
VEHICLE.


16

Installation Manual










Section 7

PUREFLOW® DIESEL SYSTEM

AirDog






INITIAL START PROCEDURE



The
AirDog™

is a self priming system, however, to prevent damage to a dry se
al 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.


RECHECK AL
L 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 ELECTRIC
AL LINES, SECURE AS
NECESSARY.



7
-
3

Start engine!



NOTE: Should
any installation problems arise, please call, toll free 1
-
877
-
463
-
4373, for assistance
(Monday


Friday, 8:00 am


5:00 pm CST).

Visit our website at
www.pureflowtechnologies.com

for updated materials an
d frequently asked
questions.