ChampII SPIN-ON Hi Pressure Fuel Air Separator For Class 8 Trucks INSTALLATION MANUAL For Trucks Equipped with DETROIT Series 60 Engines Equipped with the 23539278 Filter Head Detroit Diesel Series 60 ChampII Spin-On Kit No. A7SODE730 PLEASE READ THESE INSTRUCTIONS THOROUGHLY BEFORE BEGINNING INSTALLATION! Fuel Preporator Technology Inside 10 YEAR Limited Express Warranty Model No. HPAS-785 Providing Test Cell Performance in Real World Conditions Since 1993! 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!
ChampII Spin-On Hi Pressure Fuel Air Separator THE RIGHT CHOICE FOR YOUR DIESEL ENGINE! K No Fuel Pump K"LM" "N.*&"1$$<$$++.4" "BO9&.00":*&&*(++="K No Electrics K" Welcome to the AirDog ChampII Spin-On High Pressure Fuel Air Separation System for Class 8 Trucks The AirDog, ChampII with ADVANCED FUEL AIR SEPARATION is a premium fuel air separator for the Detroit Series 60 engine. The ChampII, installed between the secondary fuel filter head and filter, removes virtually all entrained air and vapor from the fuel flow to the engine. Diesel engines equipped with the AirDog ChampII can now perform as designed under most all operating conditions! Detroit Filter Head No. 23539258?.%.$6.0"/,.-"/-'@"A&'<" B(2$(."C&*(0A.&"),<9D" E'"B-.%+&$%"/,.-"),<9"?.F,$&.45" )'0$+$6."7$&"8.9*&*+$'("" :$+;")&$<*&="7$&" >$0%;*&2.")'&+5"!"#$%&'(")*&+$%,-*+."/$-+.&0" 1'(2"1*0+$(2"#$%&'3-*00"#.4$*5" G(+.&(*-"H;.%I"J*-6." )&.6.(+0"/,.-">&*$($(2" A&'<"B(2$(.">,&$(2" /$-+.&"H;*(2.5" Amazing Simple Installation Mounts on engine secondary fuel filter head. Air/Vapor return line connects to engine fuel return line. Shipping Weight 5 Lbs. Amazing Simple Operation Operates in conjunction with the engine fuel flow. Separates and removes entrained air plus vapor from fuel pump cavitation and fuel line pressure drop before the fuel enters the engine! 2
Section 1 Table of Contents TABLE OF CONTENTS Section 1..............Table of Contents Section 2.............Parts List CHAMPII INSTALLATION PROCEDURES Section 3.......Installing the ChampII Section 4...........Installing the Air/Vapor Return Line Filter Maintenance Section 5.......Filter Service Recommendations Detroit Secondary Fuel System Upgrade Section 6......Fuel System Upgrade Section 7..Initial Start-Up Procedure SAFETY GUIDELINES! CAUTION: CAUTION: CAUTION: Chock the vehicle s tires to prevent rolling. Wear safety glasses when operating power tools such as drills and grinders or when using a punch or chisel. Route the fuel lines keeping them away from hot exhaust components and/or moving parts. Properly secure the fuel lines to prevent chaffing. 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. 3
OVERVIEW AirDog Overview The Detroit Series 60 Secondary Fuel System Up-Grade! PureFlow Technologies, Inc. addresses diesel engine efficiency 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 flow 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! Specifically, if the fuel pressure/flow to the injector, even with entrained air and vapor removed, is insufficient to totally fill 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 retarded 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 Up-Grade Kit available for the Detroit Series 60 Engine, model years 2003 thru 2009. The Up-Grade kit is NOT included with the ChampII kit. Complete and detailed instructions are included should you decide to make your own Up-Grade kit! To order the Detroit Series 60 Up-Grade Kit or for more information, Contact PureFlow Technologies at 1.573.635.0555! SECTION 2: ChampII Installation Parts List QTY DESCRIPTION Part Number IMAGE 1 Installation Manual 207-7-0730B 1 AirDog ChampII Spin-On Air Separator HPAS-785 A7SOCA700 1 #6 - JIC Flare X 9/16-18 ORB X 90 O Return Fitting 4A2-1-01-06-06-S 1987-2002 Air/Vapor Return Fittings 1 #6 - JIC Flare x! NPT Air/Vapor Return Fitting 4A-1-01-A-C-SZ 1 #8 - Female Swivel x #8 Male Flare x! Side Port Return T 4A-1-11-08-08-4P Series 60 2003-2009 Air/Vapor Return Fittings 1 #6 - JIC Flare x 3/8 NPT Air/Vapor Return Fitting 4A-1-04-06-06-S 1 Return T 4A-4-08-06-06-B 1 Connector 4A-1-22-06-06-B 1 7 ft Pre-assembled #6 Air/Vapor Return Line 4C-1-06-06-84 4
Section 3 Installing the ChampII Installing the AirDog ChampII NOTE: Figure 1 is showing the secondary fuel filter mounted on a 2005 Detroit Series 60. 3-1. Remove the Detroit secondary fuel filter. Figure 1 Figure 2 3-2. Check the O-ring seal to be sure that it is properly installed in the Groove in the top of the ChampII. 3-3. Screw the ChampII onto the Detroit secondary fuel filter head. Figure 3 Figure 4 Part No. 23539258 NOTE: The ChampII 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 ChampII approximately 120 O apart. One or the other air/vapor return port will be accessible after tightening the ChampII. 3-4. After tightening the ChampII, remove the 9/16-18 ORB plug from the most accessible air/vapor return port. Remove Plug 3-5. Install the 9/16-18 x #6 JIC 90 O fitting into the air/vapor return port. Install Fitting Figure 5 5
Section 4 Air/Vapor Return Line Section 4: Installing the ChampII Air/Vapor Return Line! The AirDog ChampII 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. VERY IMPORTANT The AirDog ChampII Air/Vapor return T must Be installed after the Detroit Regulator/Check Valve. The valve may be attached to the 90 o fitting on the back of the head OR After a section of fuel line! Figure 6 Figure 7 Air/Vapor return T on the 1987 2002 Series 60 4-1. Disconnect the fuel return line connected to the Pressure Regulator at the back of the Series 60 head. Figure 8 Figure 9 Figure 10 4-2. Assemble the AirDog Champ Return T and install it on the outlet side of the Detroit Check Valve. Reconnect the original engine return line to the T. Air/Vapor return T on the 2003 2009 Series 60 4-3. Disconnect the fuel return line connected to the Pressure Regulator at the back of the Series 60 head. Figure 11 Figure 12 Figure 13 4-4 Assemble the AirDog Champ Return T and install it on the outlet side of the Detroit Check Valve. Reconnect the original engine return line to the T. 6
Section 4 Air/Vapor Return Line 4-4. Reconnect the original engine return line to the #8 JIC fitting on the T. #6 Air/Vapor Return Figure14 Figure 15 4-5. Install the ChampII Air/Vapor return line. The return line is included in the installation kit. Connect one end to the Air/Vapor return fitting on the ChampII. Connect the other end to the #6 JIC on the return T. 4-6. Pre-fill the fuel filter with clean fuel and install it on the ChampII. SECTION 5: Servicing the AirDog ChampII Fuel Filter It is recommended to replace the fuel filter at 25,000 miles of service. When replacing the fuel filter, be sure to clean the under side of the AirDog ChampII base. Follow the instructions on the filter for proper tightening procedures. AirDog Champ Fuel Filter 6 Micron Micro Glass Built in Check Valve Prevents fuel from draining from the engine head during filter changes. Figure 16 VERY IMPORTANT: Fuel filters are often OVER TIGHTENED and difficult to remove. It is suggested to carry a second filter wrench to use as a backup wrench when changing the fuel filter! Dispose of waste fuel and used filters properly, protect OUR environment! 7
Section 6 Fuel Line Up-Grade AirDog Series 60 Fuel Line Up-Grade OVERVIEW PureFlow Technologies, Inc. addresses diesel engine efficiency 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 flow 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! Specifically, if the fuel pressure/flow to the injector, even with entrained air and vapor removed, is insufficient to totally fill 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 retarded 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 Up-Grade Kit available for the Detroit Series 60 Engine, model years 2003 thru 2009. The Up-Grade kit is NOT included with the ChampII kit. Complete and detailed instructions are included should you decide to make your own Up-Grade kit! Contact PureFlow Technologies at 1.573.635.0555 for additional information and ordering! The Detroit Diesel Series 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 & fittings. AirDog #8 JIC x 14mm Passageway 0.375 ID Figure 17 NOTE: Secondary fuel filters are optional on Detroit Diesel Series 60 engines. Section 6A is for engines without secondary fuel filters. Section 6B is for engines WITH secondary fuel filters. Figure 18 Figure 19 14mm FOR SEAL Fitting 0.240 ID Passageway Detroit Series 60 With Out Secondary Fuel Filter. Steel line carries fuel from transfer pump directly to the engine head. 8 Detroit Series 60 With Secondary Fuel Filter
Section 6 Fuel Line Up-Grade Section 6A: Up-Grade for Series 60 Engines Without A Secondary Fuel Filter! 6A-1. Disconnect the steel fuel line from the FOR-SEAL fuel fitting at the fuel OUT port on the transfer pump and remove the OE fuel fitting. Figure 20 6A-2. Install the new Ported 16mm x #8 JIC flare fitting in the transfer pump fuel OUT port. Figure 21 Figure 22 6A-3. Disconnect the OE fuel supply line from the FOR-SEAL fuel inlet fitting at the back of the head and remove the fitting. NOTE: You may remove the OE steel fuel line from the engine. 6A-4. Install the extended 3/8 NPT x #8 JIC flare fitting into the fuel in port vacated by the FOR-SEAL fitting. Use diesel fuel compatible thread sealer on all NPT threads. Figure 23 6A-5. Measure and cut the length of fuel line required, when properly routed and secured, to make the connection from the transfer pump to the fuel inlet fitting at the back of the engine head. Assemble the fuel line per standard procedures. 9 Extended 90º 3/8 NPT x #8 JIC Flare Fitting
Section 6 Fuel Line Up-Grade Installing the Series 60 Fuel Line Up-Grade, cont d 6A-6. Connect and secure one end of the fuel line assembled in step 6A-5 to the transfer pump fuel OUT port. Figure 24 Figure 25 6A-7. Route and connect the new fuel line to the new #8 JIC flare fitting just installed in the back of the back of the engine head. Section 6B: Series 60 Engines With A Secondary Fuel Filter! 6B-1. Disconnect and remove the steel fuel line from the FOR-SEAL fuel fitting at the fuel OUT port on the transfer pump and from the secondary fuel filter, fuel in port. Figure 26 Figure 27 6B-2. Replace the FOR-SEAL fitting in the transfer pump with the 16mm x #8 JIC flare fitting. Figure 28 Figure 29 6B-3. Replace the FOR-SEAL fitting in the secondary filter with the 14mm x #8 JIC flare fitting. 10
Section 6 Fuel Line Up-Grade Section 6B: Installing the Series 60 Fuel Line Up-Grade, cont d 6B-4. Measure and cut the length of fuel line required to connect the transfer pump fuel OUT port to the secondary filter fuel IN port. Figure 30 6B-5. Assemble the fuel line with one straight and one 90º field attachable fuel line end fitting, as illustrated in Figure 31. Figure 31 Figure 32 6B-6. Attach the straight end to the transfer pump OUT port (Fig. 30) and the 90º end to the secondary fuel filter. 6B-7. Disconnect the steel fuel line and remove the shut-off valve from the secondary fuel filter. NOTE: The ChampII Has a built-in Check Valve Figure 33 Figure 34 6B-8. Install the 14mm x #8 JIC flare fitting in the out to engine port. 6B-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. Figure 35 Extended 90º 3/8 NPT x #8 JIC Flare Fitting 11 Figure 36 6B-10. Install the 90º extended 3/8 NPT x #8 JIC flare fitting into the fuel in port vacated by the FOR-SEAL fitting. Use diesel fuel compatible thread sealer on all NPT threads.
2003-09 Section 6 Fuel Line Up-Grade Section 6B: Installing the Series 60 Fuel Line Up-Grade, cont d 6B-11. Measure and cut, the length of fuel line required to connect the secondary filter OUT port to the #8 JIC fitting just installed in the back of the engine head. Figure 37 Figure 38 6B-12. Assemble the fuel line with a straight field attachable fuel line end fitting on each end. Figure 39 6B-13. Connect the one end of the new fuel line to the fuel OUT port on the secondary fuel filter. Route and connect the other end to the #8 JIC fuel fitting in the head. Figure 40 Figure 41 6B-14. Properly tighten the fuel line connections to the JIC fittings. Secure the fuel lines to prevent chaffing. 12
2003-09 Section 7 Initial Startup INITIAL START UP PROCEDURE Be sure the secondary fuel filter is pre-filled with CLEAN diesel fuel TO THE BOTTOM OF THE NUT PLATE. 7-1. Pre-fill the fuel filter with diesel fuel to the bottom of the nut plate and install the filter. 7-2. Start your engine! 7-3. Bleed the fuel line to the engine by slightly loosening the fuel line connection at the engine fitting. As soon as the line is purged of air, tighten the fuel fitting. NOTE: Put a rag or shop towel around the fitting to prevent fuel splatter or spray. Catch all spilled fuel and dispose of properly. 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 CHAFFING AND ABRASION. 13
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Copyright 2015 Bulletin No. 207-7-0730B CD Patents, LLC 16 March, 2015 All Rights Reserved