Airdog CUMMINS ISX15 User manual

INDUSTRIAL
Fuel Air Separation System
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INSTALLATION MANUAL
For Trucks Equipped with
CUMMINS®ISX15 Common Rail & X15
Part No. A3SPBT453
NOW WITH DEMAND FLOW
Providing “Test Cell Performance” in “Real World Conditions” Since 1993!
Proudly Made in the USA
www.airdogdiesel.com
1-573-635-0555 or
1-877-463-4373
PLEASE READ
THESE INSTRUCTIONS
THOROUGHLY
BEFORE BEGINNING
INSTALLATION
Revised 3/25/20

2
THE RIGHT CHOICE FOR YOUR DIESEL ENGINE
CARB Executive Orders D-595-3 & D-595U-4 permit the advertisement, sales and installation of
PureFlow Technologies AirDog®Diesel Fuel Systems in California on 2016 and older model year
on-road diesel vehicles and o-road diesel vehicles/equipment.
Low Fuel Pressure Switch
and LED Indicator
Lets you know when to service
the fuel lter and water separator
before suering power loss.
NO MORE GUESSING!
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!
LoveJoy Coupler System
The LoveJoy Coupler System is
self-aligning and eliminates
virtually all vibrations.
Dual Port Pump
Balances the gerotor for quiet
operation and higher ows.
Protective Wire Screen
In water separator nipple.
6 Micron Particulate Filters
Long-Lasting MicroGlass Media
Water Separator/Prelter
Long-Lasting Wire Mesh Media
Bearings
Positive Air Separation
with primary air discharge port.
Demand Flow System
Easy installation, only one small line
connected to the engine return line to
return air/vapor to the tank.
Adjustable Regulator
For just the right fuel pressure.
INDUSTRIAL
Fuel Air Separation System

3
SYSTEM OVERVIEW
Welcome to the AirDog®Heavy Duty Industrial
Fuel Air Separation System for Class 8 Trucks
The AirDog®, with ADVANCED FUEL AIR SEPARATION, DEMAND FLOW, ADJUSTABLE
REGULATOR, LOW PRESSURE SENSOR with LED INDICATOR and the 4G-HD FUEL
PUMP, is a premium fuel ltration and delivery system for the Cummins ISX15 Common Rail &
X15 Diesel Engines.
The “VACUUM FEED FILTER SYSTEM” currently on your engine passes entrained air to the
engine and increases cavitation and vapor as the fuel lter plugs with use!
With Air & Vapor present in the fuel, the eective stroke of the High Pressure Pump and output
volume of fuel to the Common Rail is reduced. This adversely aects both the injection rate and
also the shape of the injection spray pattern, which results in increased fuel consumption and
increased exhaust emissions.
AirDog®removes the entrained air from the fuel and prevents the formation of vapor in the high
pressure pump to restore the eciency of the Common Rail System.
Diesel engines, regardless of which type of fuel injection system they may have, when 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 entrained air from the
fuel owing to your engine. The entrained air and vapor separated from the fuel is returned to
the fuel tank. The fuel ow to the engine’s transfer pump is maintained at a NET POSITIVE
PRESSURE HEAD preventing cavitation and the formation of vapor thus overcoming the
performance related problems from plugged fuel lters, torque loss at higher engine RPM, and
high altitude operation.
All AirDog®products are manufactured with a personal touch,
unsurpassed attention to detail and the most stringent quality assurance!
TYPICAL INSTALLATION LAYOUT
Figure 1
The AirDog®requires only one small return line connected to the engine return line, for quick
and easy installations.
Pure Fuel to Engine
at Positive Pressure Entrained Air in Fuel
from Agitation & Sloshing
AirDog®Air/Vapor Return Line
Fuel Supply Line
Engine Air/Vapor Return Line

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PureFlow®Technologies Inc.
AirDog®FPII-200 Cummins®ISX15 & X15
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 5A & B………...…..……….........Mounting the AirDog®& Mounting Brackets
Fuel Lines, Fittings & Low Fuel Pressure Sensor Switch
Section 6A........................................................................Fittings & Fuel Pressure Sensor
Section 6B….….…..…....…..........................................AirDog® Air/Vapor Return Line
Section 6C……..….....................................................Fuel Line from Tank & to Engine
Wiring Harness
Section 7…..….……....…..……………..………....…….............….......Wiring Harness
Section 8..……….…..……….…………................….…….…...........…Initial Start Up
Maintenance
Section 9..………...…….….……...........................................................…Filter Service
Section 1 Table of Contents

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PureFlow®Technologies Inc.
AirDog®FPII-200 Cummins®ISX15 & X15
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 PureFlow® Technologies, Inc.,
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 ttings 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
ange 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 chang.
If you are uncertain of any installation procedure, please call:
PureFlow®Technologies, Inc. at 573-635-0555 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.

6
PureFlow®Technologies Inc.
AirDog®FPII-200 Cummins®ISX15 & X15
PLEASE NOTE Due to the many variables in components and arrangement of those components
in the many dierent truck models, the AirDog® installation kit contains only the basic fuel ttings
needed to install the AirDog® using existing fuel lines.
Section 3 Parts List
1 16 mm M ORB x 16 mm F ORB x 908-09-0100-M
#6 M JIC Air/Vapor Return Fitting
(Available only from PureFlow Technologies)
2 # 6 F JIC Swivel x 3/8” Pushlock Hose Barb 4A-1-09-06-06-B
1 #6 F JIC Swivel x #6 M JIC Swivel 90° Elbow 4A-2-04-06-06-S
908-01-0453-RLFK Return Line Fitting Kit
1 Installation Manual 206-1-0453
1 AirDog®- with Serial Number Plate
FPII-200-LP
1 Wiring Harness with Indicator Light 5E-2-010
1 Fuel Filter Monitor Light Plate 201-3-0004-S
1 7 ft. Section DOT Air/Vapor Return Line 4C-1-02-05-010-7FT
2 #10 M JIC x 1/2” M NPT Straight Adapter 4A-1-01-10-08-S
2 #10 F Swivel x #10 M JIC 90° Elbow 4A-2-04-10-10-S
1 #6 M JIC x 1/4” M NPT Straight Adapter 4A-1-01-A-C-SZ
1 Grommet 5J-1-1-04-2758
908-08-0800 AirDog®FPII Basic Fitting Kit
Fuel Filter FF200-MG-6
Water Separator WS200-WS
QTY Description Part Number Image
908-00-0304 Frame Mount Kit
2 Mounting Bracket 002-3C-0003
002-3C-0004
1 901-08-0100 Hardware Kit, Includes:
4 ea 3/8” x 1-1/4” Hex Head Bolts 1J-1-C20SZ
4 ea 3/8” Nuts 1S-1-CSZ
4 ea 3/8” Lock Washers 1R-6-CSZ
4 ea 1/4-20 x 2” SHC Screws 1L-A32C
4 ea 1/4” Lock Washers 1R-6-AC
4 ea 1/4-20 Hex Nuts 1S-1-AC
1 Fuel Pressure Sensor 5 psi 908-5C-9-007
ADFK-453 Installation Kit
SBK-1000 Sandwich Bracket Kit
1 901-08-0100-SB Hardware Kit, Includes:
3 ea 3/8”-16 x 3-1/2” Hex Head Bolts 1J-1-C56SZ
7 ea 3/8” Nuts 1S-1-CSZ
7 ea 3/8” Lock Washers 1R-6-CSZ
1 Sandwich Mounting Bracket Kit for AirDog®& Champ 002-3C-0010-SBF
Includes: 1 Front - 1 Back & 002-3C-0011-SBB
1 Center Bracket 002-3C-0006PCB
OPTIONAL

7
PureFlow®Technologies Inc.
AirDog®FPII-200 Cummins®ISX15 & X15
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:
• 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!
NOTE: On various class 8 trucks, the manufacturer may use other than traditional steel braid fuel
lines. These lines require special ttings. The ttings used with the original primary fuel lter are
specic 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 ttings.
The following examples, Figures 2 thru 5, show dierent AirDog® installations. There are many
variations in the arrangements and the components on the various trucks. With a little ingenuity, the
AirDog® can be successfully installed on any class 8 truck.
Figure 2 shows the original fuel lter mounted on a bracket to the rear of the engine
compartment and just above the frame behind the steering column.
Figure 2
Figure 3
Figure 3 shows the primary fuel lter mounted on the frame.
In Figure 4, the AirDog® is mounted on the original fuel lter bracket high above the frame
and toward the front of the engine compartment.
Figure 4
Figure 5
The installation in gure 5 shows the AirDog®mounted on the frame on the passengers side, up
front by the radiator.

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PureFlow®Technologies Inc.
AirDog®FPII-200 Cummins®ISX15 & X15
Section 5 Mounting the AirDog®
Section 5: Mounting AirDog® on the Truck’s Frame (Drilling Method)
NOTE: Do Not mount the AirDog® on the engine! Mounting the AirDog®on the engine will
immediately void the AirDog® warranty. Mount the AirDog® on the truck frame.
5A-1. Remove the original primary fuel lter from the vehicle.
Figure 6
Figure 7
5A-2. Hold the AirDog® with the brackets and lters attached next to the frame.
5A-3. Turn the steering wheel fully to the left and to the right to check for tire clearance.
Figure 8
Figure 9
5A-4. Mark and center punch each hole location.
5A-5. Drill a 3/8” hole at each of the 4 previously marked locations.
WARNING! USE CARE NOT TO DRILL INTO OR DAMAGE ANY WIRING, AIR LINES
OR OTHER COMPONENTS LOCATED BEHIND THE FRAME RAIL.
Figure 10 Figure 11
5A-6. Loose assemble the mounting brackets and AirDog® to the frame. After mounting the
AirDog® on the brackets, snug the fasteners to achieve a good relaxed t, then nish tightening all of
the fasteners.

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PureFlow®Technologies Inc.
AirDog®FPII-200 Cummins®ISX15 & X15
Section 5 Mounting Brackets
Sandwich bracket comes with all hardware that is needed and NO DRILLING
Sandwich bracket can be used in any combination of ways to t your truck.
Sandwich bracket slides right
over existing frame.
OPTIONAL KIT AVAILABLE (PN: SBK-1000)
NO DRILL Universal Sandwich Mounting Bracket

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PureFlow®Technologies Inc.
AirDog®FPII-200 Cummins®ISX15 & X15
Section 5 Mounting the AirDog®
Mounting the AirDog® on the original lter bracket
5B-1. Remove the original fuel lter from the mounting bracket (Figure 13).
Figure 12 Figure 13
5B-2. Attach the AirDog® mounting brackets to the original lter plate. If the original bracket is not
wide enough to t the AirDog® brackets, bolt a plate to the bracket.
Figure 14 Figure 15
5B-3. Loosely assemble the brackets to the plate and the AirDog® to the brackets.
5B-4. After mounting the AirDog® on the brackets, snug the fasteners to achieve a good relaxed t,
nish tightening all of the fasteners.
NOTE: These steps are necessary to prevent stress cracks from forming in the mounting brackets
due to vibration.
Assembly Instruction for Hose Barb
1. Cut hose line to length.
2. Apply oil to tting.
3. Push tting into line until seated.