Airdog A3SPBT403 Installation Manual Download Page 1

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INDUSTRIAL

Fuel Air Separation System

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!

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

Summary of Contents for A3SPBT403

Page 1: ...20 PL10 2021 Additional Foreign Patents Issued and Pending in Europe South America Japan and China 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...

Page 2: ... 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 flows Protective Wire Screen In water separator nipple 6 Micron Particulate Filters Long Lasting MicroGlass Media Water Separator Prefilter L...

Page 3: ...s 60 engine model years 2003 thru 2009 utilizes FOR SEAL fittings with steel lines on the high pressure side of the transfer pump These fittings have small passageways and are restrictive to the fuel flow to the engine To maximize the efficiency of the 2003 THRU 2009 Series 60 engine it is necessary to replace the restrictive fuel fittings and lines with the larger and less restrictive lines fitti...

Page 4: ...acket Kit Fuel Lines Fittings Low Fuel Pressure Sensor Section 6A Fittings Fuel Pressure Sensor Section 6B Fuel Line fromAirDog 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 Sectio...

Page 5: ...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 a...

Page 6: ... 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 Basi...

Page 7: ...ervice 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 different 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...

Page 8: ...This picture finds space to mount the AirDog on a bracket in the location of the original primary fuel filter 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 ...

Page 9: ...l 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 fit your truck Sandwich bracket slides right over existing frame Section 5 Optional Bracket Kit OPTIONAL KIT AVAILABLE PN SBK 1000 ...

Page 10: ...fuel supply line from the fuel tank and also the fuel line to the engine 5 2 Loosely assemble the mounting brackets and filters to the AirDog 5 3 Hold the AirDog with the brackets and filters 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 Sec...

Page 11: ...S OR OTHER COMPONENTS LOCATED BEHIND THE FRAME RAIL 5 6 Loosely assemble the mounting brackets to the frame 5 7 Mount and loosely assemble the AirDog on the brackets 5 8 After mounting the AirDog on the brackets snug the fasteners to achieve a good relaxed fit 5 9 Properly tighten all of the fasteners NOTE These steps are necessary to prevent stress cracks from forming in the mounting brackets due...

Page 12: ...unt the AirDog in the location that will allow the use of the original fuel lines and fittings Inspect the original fuel lines for size length and condition If the fuel lines are in good condition and the correct size and length to adequately reach the AirDog you may want to go ahead and use them If any of the fuel lines need to be replaced it is recommended that the fuel lines selected meet or ex...

Page 13: ... sealer when installing NPT fittings NOTE Pictures below illustrate the installation of straight fittings 8 JIC and 10 JIC fittings have been included you will use one or the other based on your fuel line size In some instances 90º fittings may be required to connect the fuel lines to the AirDog Therefore 90º fittings have also been included in the kit 6A 1 Install the straight 10 or 8 JIC x NPT f...

Page 14: ...y to the engine fuel return line Be sure to connect it after the pressure regulator NOTE it is recommended to use a 6 size line included in kit for the Air Vapor return Connecting the AirDog Air Vapor return to the engine fuel return line 6C 1 Disconnect the fuel return line connected to the Rail Pressure Regulator at the back of the head A curved 90º fuel line fitting was used with this installat...

Page 15: ...e fitting in the engine return line at the fuel tank 6C 6 The filter assembly has return fuel from the engine running through it to heat the incoming fuel When removing this filter re connect the return line from the engine to the return line to the tank with the 3 8 Tee Connect the AirDog return line at the Tee 6C 7 Measure and cut a length of fuel line required when properly routed to connect fr...

Page 16: ...it Series 60 Fuel Line Upgrade OR continue on to page 26 for start up procedure 6D 4 Connect the fuel supply line from the fuel tank to the fitting Secure the line to prevent chafing and abrasion Section 4 AirDog Detroit Series 60 Fuel Line Upgrade Overview The Detroit Series 60 engine utilizes FOR SEAL fittings with steel lines on the high pressure side of the transfer pump These fittings have sm...

Page 17: ... fuel supply line from the FOR SEAL fuel fitting at the back of the head and remove the fitting NOTE You may remove the OE steel fuel line from the engine 7A 4 Install the extended 3 8 NPT x 8 JIC 90 elbow into the fuel in port vacated by the FOR SEAL fitting Use diesel fuel compatible thread sealer on all NPT threads Extended 90 3 8 NPT x 8 JIC Fitting 7A 5 Measure and cut the length of the fuel ...

Page 18: ... on the transfer pump and from the secondary fuel filter fuel in port 7B 2 Replace the FOR SEAL fitting in the transfer pump with the Ported 16mm ORB x 8 JIC fitting OR the Ported 1 4 M NPT x 8 M JIC fitting 7B 3 Replace the FOR SEAL fitting in the secondary filter with the Ported 14mm x 8 JIC fitting OR the Ported 1 4 M NPT x 8 M JIC fitting OR 7A 8 Properly tighten all fuel line connections and ...

Page 19: ...he transfer pump OUT port and the 90 end to the secondary fuel filter 7B 8 Install the Ported 14mm x 8 JIC fitting OR the Ported 1 4 M NPT x 8 M JIC fitting in the Out to Engine port 7B 9 Disconnect the OE fuel supply line from the FOR SEAL fuel inlet fitting at the back of the head Remove the steel line and fitting 7B 10 Install the 90 extended 3 8 NPT x 8 JIC fitting into the fuel in port vacate...

Page 20: ...to the 90 8 JIC fitting just installed in the back of the engine head 7B 12 Assemble the fuel line with a straight field attachable fuel line end fittings on each end 7B 13 Connect the end of the new fuel line to the fuel OUT port on the secondary fuel filter Route and connect the other end to the 90 8 JIC fuel fitting in the head 7B 14 Properly tighten all fuel line connections and fittings Secur...

Page 21: ...he AirDog Wiring Harness Relay to the Vehicle 8 1 Secure the AirDog wiring harness relay to the vehicle This picture shows the relay mounted on the firewall 8 2 Route the AirDog wiring harness pump motor lead and the fuel pressure sensor lead to the AirDog unit Connect the wiring harness pump motor lead to the AirDog unit pump motor lead 8 3 Connect the AirDog wiring harness fuel pressure sensor l...

Page 22: ...ad to a point that is HOT when the key is in the ACCESSORY position 8 5 Route the AirDog wiring harness trigger lead red wire with no connector plug and indicator light lead through the firewall Routing the Indicator Light and Relay Trigger Lead through the firewall 8 4 Most Peterbilts and Kenworths have access holes located below the steering column Remove the plug and route the leads through the...

Page 23: ... ignition switch that is HOT when the ignition key is in the RUN position OR connect the red relay trigger lead to a fuse holder in the fuse panel that is HOT when the ignition key is in the RUN position THIS OR THIS INSTALLING THE AIRDOG WIRING HARNESS INDICATOR LIGHT Amber LED Indicator Light 8 7 Select a location on the dash that is easily visible to the driver Remove the dash components as nec...

Page 24: ...dash Reinstall nut and tighten until snug Connect the AirDog wiring harness indicator light lead to the connector on the wiring harness 8 10 Re assemble the dash components back to their original position Installing the Indicator Light Cont d CONNECTING THE POWER SUPPLY LEADS The power supply leads can be easily connected to the appropriate contacts on the alternator Any high amperage terminal tha...

Page 25: ...ottom of the nut plate r 9 3 Turn the starter key to the on run position r 9 4 The AirDog should now be running and pumping fuel bleed the fuel line to the engine by loosening the fuel line connection at the engine fitting As soon as the line is purged of air and pure fuel is observed properly tighten the fuel fitting NOTE Put a rag or shop towel over and around the fitting to prevent fuel splatte...

Page 26: ...enting sufficient operating pressure flow to the engine the Indicator Light will immediately illuminate Check the water separator pre filter for plugging Clean or replace as necessary If the light continues to be on check the screen in the water separator pre filter nipple for debris and plugging Clean as necessary Replace the water separator if it becomes damaged or permanently plugged Servicing ...

Page 27: ...NOTES ...

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