PureFlow AirDog A7SODE730 User manual

PATENT
www.AirDogDiesel.com/patents
INSTALLATION MANUAL
For Detroit Series 60 Engines
Equipped with a Spin-On Secondary Fuel Filter Housing
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
“SPIN-ON”
High Pressure Fuel Air Separator
Revised 10/18/22
PLEASE READ
THESE INSTRUCTIONS
THOROUGHLY
BEFORE BEGINNING
INSTALLATION
Part No. A7SODE730

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The AirDog®Champ II is proudly made in the USA.
sImproves Fuel Mileage
sLengthens Injector Life
sSmoother Idle
sImproves Throttle Response
sMaximizes Torque
sReduces Emissions
Proudly made in the USA
With PureFlow Technologies AirDog®Champ
II system installed, your diesel engine can
perform as designed even under the most
extreme conditions.
877-GO-DIESEL (877-463-4373)
airdogdiesel.com
™
Amazingly Simple Installation
Spins on between filter head and
the fuel filter. Air/Vapor return line
connects to engine fuel return line.
Amazingly Simple Operation
Operates in conjunction with the
fuel flow and pressure created by the
engines transfer pump. Separates
and removes entrained air plus
vapor from fuel pump cavitation
before the fuel enters the engine.

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PureFlow®Technologies, Inc.
AirDog®Champ II Detroit Series 60 Engines
TABLE OF CONTENTS
Section 1………….........…….…...………............…..…………..….Table of Contents
Section 2……………………..........…………………Installation and Safety Guidelines
Section 3……………………..........………………………………………..…Parts List
Section 4……………...........………...........................................….....System Overview
INSTALLATION PROCEDURES
Section 5………………..........………………..............Installing the AirDog® Champ II
Section 6………………………...............................Installing theAir/Vapor Return Line
OPTIONAL DETROIT SECONDARY FUEL SYSTEM UPGRADE
Section 7……..…………............…............................….............Fuel System Upgrade
Section 8.………………..........................................…….....Initial Start-Up Procedure
MAINTENANCE
Section 9..…………………………....................................................……Filter Service
Section 1 Table of Contents
Section 2: 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
missing or damaged parts.
2. Read the installation manual completely. Understand how the system operates and the
installation recommendations before beginning.
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: 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, 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.

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PureFlow®Technologies, Inc.
AirDog®Champ II Detroit Series 60 Engines
1 #6 Hose w/end ttings 7’ L Hose Assembly 4C-1-06-06-84
Section 3 Parts List
Installation Parts List
Section 4: System Overview
PureFlow® Technologies, Inc. addresses diesel engine eciency and peak performance on the
fuel side, from the fuel tank to the tip of the injector. Removing entrained air and fuel vapor
from the fuel ow to the engine is not enough if the internal conditions of the fuel system
components are such to allow vapor to form in the injector itself.
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.
To overcome these concerns, PureFlow® Technologies has an “Upgrade Kit” available for the
Detroit Series 60 Engine. The “Upgrade” kit is NOT included with the Champ II installation
kit, although the complete and detailed instructions are included.
QTY Description Part Number Image
1 Installation Manual 207-7-0730
1 AirDog® Champ II High Pressure Air Separator CHPII-730-WIP
1AirDog® Fuel Filter FF200-MG-6
1 #6M JIC x 3/8 M ORB 90⁰ Elbow 4A-2-01-06-06-S
1
#6M JIC x 1/4 M NPTF Straight Connector 4A-1-01-A-C-SZ
1 #8M JIC x #8F JICX x 1/4 NPTF Port GagePort 4A-1-11-08-08-4P
1 #6M JIC x 3/8 F NPTF Straight Connector (Return Fitting) 4A-1-04-06-06-S
1 3/8 M SAE x 3/8 M SAE x 3/8 M NPTF Tee 4A-4-08-06-06-B
1 #6F SAEX x #6F SAEX Union Swivel 4A-1-22-06-06-B
970-07-0730 Installation Fitting Kit
Contact PureFlow®Technologies at 1-573-635-0555 for additional information and ordering.

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PureFlow®Technologies, Inc.
AirDog®Champ II Detroit Series 60 Engines
Remove Plug
Install
Fitting
Figure 4
Section 5 Installing the Champ II
Figure 3
Figure 2
Figure 1
Section 6: Installing the Champ II Air/Vapor Return Line
The AirDog® Champ II returns entrained air & vapor to the fuel tank. It is best to connect
the Air/Vapor return line directly to the engine fuel return line. Be sure to connect it after the
pressure regulator. (Figures 5 & 6)
VERY IMPORTANT: The AirDog® Champ II
Air/Vapor return “T” must be installed after the
Detroit Regulator/Check Valve. The valve may
be attached to the 90° tting on the back of the
head (B) OR after a section of fuel line (A).
Figure 5 Figure 6
Section 5: Installing the AirDog® Champ II
NOTE:Figure1isshowingthesecondaryfuelltermountedona2005DetroitSeries60.
5-1. Remove the Detroit
secondaryfuellter.
(Figure 1)
5-2. Check the O-ring
seal to be sure that it is
properly installed in the
“Groove” in the top of
the Champ II. (Figure 2)
5-3.ScrewtheChampIIontotheDetroitsecondaryfuellterhead.(Figure3)
NOTE: The Champ II is a “spin-on” unit and once it has been
tightened we cannot determine the accessibility of the Air/Vapor
return port. Therefore, we have machined two Air/Vapor return
ports into the Champ II approximately 120° apart. One or the other
air/vapor return port will be
accessible after tightening the
Champ II.
5-4. After tightening the Champ II,
remove the 3/8” ORB plug from the
most accessible air/vapor return port.
(Figure 4)
5-5.Installthe3/8”ORBx#6JIC90°elbowttingintothe
air/vapor return port. (Figure 4)

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PureFlow®Technologies, Inc.
AirDog®Champ II Detroit Series 60 Engines
Section 6 Air/Vapor Return Lines
Figure 7
Figure 8
Figure 9 Figure 10 Figure 11
Figure 12 Figure 13 Figure 14
6-7.Pre-llthefuellterwithcleanfuelandinstallitontheChampII.
Connect the other end to the #6 JIC on the Return Tee. (Figure 12)
6-1. Disconnect the fuel return line connected to the pressure
regulator at the back of the Series 60 head. (Figure 7)
6-2. Assemble the AirDog® Champ
II Return Tee and install it on the
outlet side of the Detroit Check
Valve. Reconnect the original engine
return line to the Tee. (Figure 8)
6-3. Disconnect the fuel return line connected to the pressure regulator at the back of the Series 60
head. (Figure 9)
Air/Vapor Return Tee on the 2003-2009 Series 60
Air/Vapor Return Tee on the 1987-2002 Series 60
Section 6: Installing the Champ II Air/Vapor Return Line, cont’d
6-4. Assemble the AirDog®Champ II Return Tee (Figure 10) and install it on the outlet side of the
Detroit check valve. (Figure 11)
6-5. Reconnect the original engine return line to the #8 JIC
ttingontheTee.(Figure12)
6-6. Connect one end of the Air/Vapor return line (Figure 13), included in the installation kit, to the
Air/VaporreturnttingontheChampII.(Figure14)

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PureFlow®Technologies, Inc.
AirDog®Champ II Detroit Series 60 Engines
Section 7 Fuel Line Upgrade
The Detroit Diesel Series 60®engine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Series60®engine, it is necessary
toreplacetherestrictivefuelttingsandlineswiththelargerandlessrestrictivelines&ttings.
(Figure 15)
Figure 15
AirDog®
#8 JIC x 14mm
Passageway 0.375” ID
14mm “FOR SEAL” Fitting
0.240” ID Passageway
7-1.Disconnectandremovethesteelfuellinefromthe“FOR-SEAL”fuelttingatthefuel“OUT”
portonthetransferpumpandfromthesecondaryfuellter,
fuelinport.(Figures16&17)
7-2. Replace the “FOR-SEAL”
ttinginthetransferpumpwith
the “Ported” 16mm ORB x #8
JICttingOR the “Ported”
1/4”MNPTx#8MJICtting.
(Figure 18)
Figure 16 Figure 17
7-3.Replacethe“FOR-SEAL”ttinginthesecondarylterwiththe“Ported”14mmx#8JIC
ttingORthe“Ported”1/4”MNPTx#8MJICtting.(Figure19)
Optional Kit available from PureFlow Technologies, Inc. - this kit is NOT
included but recommended for optimal fuel system performance.
Section 7: OPTIONAL AirDog®Detroit Series 60 Fuel Line Upgrade
OR continue on to page 10 for start-up procedure...
OR
Figure 18
Figure 19
OR
16mm
14mm
1/4” NPT
1/4” NPT

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PureFlow®Technologies, Inc.
AirDog®Champ II Detroit Series 60 Engines
Section 7 Fuel System Upgrade
7-7.Disconnectandremovethesteelfuellineandshut-ovalvefromthesecondaryfuellter
outlet. (Figure 23)
Figure 21
Figure 23
90º end
Figure 22
7-8. Install the“Ported”14mmx#8JICttingOR the “Ported” 1/4”MNPTx#8MJICttingin
the Out to Engine port. (Figure 22)
Section 7: OPTIONAL AirDog®Detroit Series 60 Fuel Line Upgrade
7-5.Assemblethefuellinewithonestraightandone90°eld
attachablefuellineendtting,asillustratedinFigure21.
7-6. Attach the straight end to the transfer pump “OUT”
port(Figure20)andthe90°endtothesecondaryfuellter.
(Figure 22)
Figure 20
7-4. Measure and cut the length of the fuel line required to connect the transfer pump fuel “OUT”
porttothesecondarylterfuel“IN”port.
7-9.DisconnecttheOEfuelsupplylinefromthe“FOR-SEAL”fuelinletttingatthebackofthe
head.Removethesteellineandtting.(Figure24)
7-10.Installthe90°extended3/8”NPTx#8JICttingintothefuelinportvacatedbythe“FOR-
SEAL”tting.UsedieselfuelcompatiblethreadsealeronallNPTthreads.(Figure25)
Figure 24
Figure 25
OR
14mm
1/4” NPT

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PureFlow®Technologies, Inc.
AirDog®Champ II Detroit Series 60 Engines
Section 7 Fuel System Upgrade
7-13.Connectoneendofthenewfuellinetothefuel“OUT”portonthesecondaryfuellter.Route
andconnecttheotherendtothe#8JICfuelttinginthehead.(Figures29&30)
7-14.Properlytightenallthefuellineconnectionsandttings.Securethefuellineswiththe
includedziptiestopreventchang.
Section 7: OPTIONAL AirDog®Detroit Series 60 Fuel Line Upgrade
Figure 29 Figure 30
7-12.Assemblethefuellinewithastraighteld
attachablefuellineendttingoneachend.(Figure28)
Figure 28
Figure 26
Figure 27
7-11.Measureandcutthelengthoffuellinerequiredtoconnectthesecondarylter“OUT”portto
the90°#8JICttingjustinstalledinthebackoftheenginehead.(Figures26&27)

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PureFlow®Technologies, Inc.
AirDog®Champ II Detroit Series 60 Engines
Section 8: Initial Start-Up Procedure
Besurethesecondaryfuellterispre-lledwithCLEAN diesel fuel TO THE BOTTOM OF THE
“NUT PLATE”.
r8-1.RubCLEANdieselfueloroilonltersealsbeforeinstallingtoensureaproperseal.
r8-2.Pre-llthefuellterwithdieselfueltothebottomofthenutplateandinstallthelter.
r8-3. Start your engine.
r8-4. Bleed the fuel line to the engine by slightly loosening the fuel line connection at the engine
tting.Assoonasthelineispurgedofair,tightenthefueltting.
NOTE:Putaragorshoptoweloverandaroundthettingtopreventfuelsplatterorspray.Catch
all spilled fuel and dispose of properly. Wear safety glasses.
RECHECK ALL FUEL FITTINGS FOR LEAKAGE AND PROPER TORQUE. BE SURE
ALL LINES ARE PROPERLY ROUTED TO PROTECT FROM EXCESSIVE HEAT AND
SECURED TO PROTECT FROM CHAFING AND ABRASION.
Section 8 Start-Up Procedure