Airdog DETROIT 60 Series User manual

INDUSTRIAL
Fuel Air Separation System
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INSTALLATION MANUAL
DETROIT SERIES 60®ENGINES
Model Years 2003 - 2009
Part No. A3SPBT403
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 8/05/2020

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

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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 Detroit Diesel Series 60®engine,
model years 2003 thru 2009.
Specically, if the fuel pressure/ow to the injector, even with entrained air and vapor
removed, is insucient to totally ll the injector barrel on the up stroke of the plunger, a void
or low pressure will form that allows vapor to re-form within the injector. The result, “injector
lag”, is just another name for “delayed injection timing”. No matter what term is used, it leaves
the engine with increased fuel consumption, lost power, and increased exhaust emissions.
The Detroit Diesel Series 60® engine, model years 2003 thru 2009, utilizes “FOR-SEAL” ttings
with steel lines on the high pressure side of the transfer pump. These ttings have small passageways
and are restrictive to the fuel ow to the engine. To maximize the eciency of the 2003 THRU 2009
Series 60® engine, it is necessary to replace the restrictive fuel ttings and lines with the larger and
less restrictive lines & ttings.
The “UPGRADE” kit is NOT included with the Detroit installation kit, although the complete
and detailed instructions are included.
Contact PureFlow®Technologies at 1.573.635.0555 for additional information and ordering.
All AirDog®products are manufactured with a personal touch,
unsurpassed attention to detail, and the most stringent quality assurance!
TYPICAL INSTALLATION LAYOUT
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
Air/Vapor Return Line
Fuel Supply Line
Entrained Air in Fuel
from Agitation & Sloshing
Fuel Preporator®
Transfer Pump

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PureFlow®Technologies, Inc.
AirDog®FPII-150 Detroit Series 60 2003-09
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® & Bracket Kit
Fuel Lines, Fittings & Low Fuel Pressure Sensor
Section 6A........................................................................Fittings & Fuel Pressure Sensor
Section 6B……..…...…...........................………........Fuel Line from AirDog®to Engine
Section 6C….….….......…..................................................AirDog®Fuel Return to Tank
Section 6D…............…….....……..........………………………..From Tank to AirDog®
OPTIONAL Fuel System Upgrade (Sold as Separate Kit, Not Included)
Section 7A......................................................Engines Without a Secondary Fuel Filter
Section 7B...........................................................Engines With a Secondary Fuel Filter
Section 8….....……....................…..……....………….….………....…..Wiring Harness
Section 9..……......….…...............….…..….................….………...……Initial Start Up
Maintenance
Section 10.……….........................…............…..............................………Filter Service
Section 1 Table of Contents

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PureFlow®Technologies, Inc.
AirDog®FPII-150 Detroit Series 60 2003-09
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.

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PureFlow®Technologies, Inc.
AirDog®FPII-150 Detroit Series 60 2003-09
Installation Parts List
Section 3 Parts List
1 #6 M JIC x 3/8” F NPT Return Fitting 4A-1-04-06-06-S
1 3/8” Return Tee 4A-4-08-06-06-B
1 #6 x #6 F Union Swivel 4A-1-22-06-06-B
2 # 6 F JIC Swivel x 3/8” Pushlock Hose Barb 4A-1-09-06-06-B
1 #6 F Swivel x #6 M JIC 90° Elbow 4A-2-04-06-06-S
1 3/8” Street Tee 4A-4-01-06-S
1 #6 M JIC x 3/8” M NPT Straight Adapter 4A-1-02-06-06-S
908-01-0403-RLFK Return Line Fitting Kit
1 Installation Manual 206-1-0403
1 AirDog®- with Serial Number Plate
FPII-150
1 Wiring Harness with Indicator Light 5E-2-010
1 Fuel Filter Monitor Light Plate 201-3-0004-S
1 3/8” Low Pressure Hose (Air/Vapor Return Line) - 7 ft Section 4C-1-02-05-010-7FT
1 Fuel Pressure Sensor 908-5C-9-007 or
908-5C-9-0010
ADFK-403 Installation 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
2 #10 M JIC x 1/2” M NPT Straight Adapter 4A-1-01-10-08-S
2 #10 F JIC Swivel x #10 M JIC 90° Elbow 4A-2-04-10-10-S
2 #8 M JIC x 1/2” M NPT Straight Adapter 4A-1-01-08-08-S
2 #8 F JIC x 8 M JIC 90° Elbow 4A-2-04-08-08-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-UNIV AirDog®FPII Basic Fitting Kit - Universal Applications
SBK-1000 Sandwich Bracket Kit
1 901-08-0100-SB Hardware Kit Includes:
4 ea 3/8”-16 x 1” Socket Head Cap Screw 1M-C16SZ
3 ea 3/8”-16 x 3-1/2” Hex Head Bolt 1J-1-C56SZ
3 each 3/8”-16 x 4-1/2” Hex Head Bolt 1J-1-C72SZ
7 ea 3/8” Nut 1S-1-CSZ
7 ea 3/8” Lock Washer 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
1 901-08-0100 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 ea 1/4-20 x 2” Socket Head Cap Screw 1L-A32C
4 ea 1/4” Lock Washer 1R-6-AC
4 ea 1/4-20 Hex Nut 1S-1-AC

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PureFlow®Technologies, Inc.
AirDog®FPII-150 Detroit Series 60 2003-09
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 lter 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!
Pictures below show examples of dierent AirDog®installations. There are many
variations in the arrangements of the components on the various trucks. With a
little ingenuity, the AirDog® can be successfully installed on any Class 8 Truck.
This installation shows the AirDog® mounted under the steering column ahead of the shock absorber.
Plenty of room here!
NOTE: Check for clearance with the tire turned both toward and away from the AirDog®.
Section 4 Selecting the Best Mounting Location

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PureFlow®Technologies, Inc.
AirDog®FPII-150 Detroit Series 60 2003-09
Selecting the Best Mounting Location, cont’d
This picture nds space to mount the AirDog®on a bracket
in the location of the original primary fuel lter.
This installation on a short nose “Day Cab”
is on the driver’s side, behind the battery
box.
This shows space to mount the
AirDog®to the rear of the shock
absorber.
Section 4 Selecting the Best Mounting Location

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PureFlow®Technologies, Inc.
AirDog®FPII-150 Detroit Series 60 2003-09
NO DRILL Universal Sandwich Mounting Bracket
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.
Section 5 Optional Bracket Kit
OPTIONAL KIT AVAILABLE (PN: SBK-1000)

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PureFlow®Technologies, Inc.
AirDog®FPII-150 Detroit Series 60 2003-09
Mounting the AirDog® on the Truck’s Frame (Drilling Method)
5-1. Disconnect the fuel lines and remove the primary fuel lter.
NOTE: Mount the AirDog® as close to the location of the primary fuel lter 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.
5-2. Loosely assemble the mounting brackets and lters to the AirDog®.
5-3. Hold the AirDog®, with the brackets and lters 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.
Section 5 Mounting the AirDog®
5-4. Hold the AirDog® at the selected mounting location on the frame. Mark and center punch
each hole location.