industrial The Original Fuel Air Separation System For All Model Years CUMMINS N-14 Diesel Engines With Pump Mount Primary Fuel Filter PLEASE READ THESE INSTRUCTIONS THOROUGHLY BEFORE BEGINNING INSTALLATION Kit No. A3SPBT402 Providing Test Cell Performance in Real World Conditions Since 1993! PROTECTED BY CANADA US PATENTS MEXICO 2,108,391 5,355,860; 5,746,184; 6,729,310 270409 NEW ZEALAND ITALY AUSTRALIA 532356 1362177 2005101054 Additional Patents Issued & Pending in Europe, South America, and China!
industrial THE RIGHT CHOICE FOR YOUR DIESEL ENGINE! With POSITIVE Fuel Air Separation, Microprocessor and the NEW 4G-HD Fuel Pump! (4 th Generation Heavy Duty) Micro Processor Fuel Filter Monitoring Lets you know when to Service the Fuel Filter & Water Separator before suffering power loss NO MORE GUESSING! Quick Change Motor If necessary, the motor can be removed and replaced in a matter of minutes. Dual Port Pump Balances the Gerotor for Quiet Operation and Higher Flows! Positive Air Separation With Primary Air Discharge Port Adjustable Regulator For Just the Right Fuel Pressure! Demand Flow System! Easy Installation, Only One Small Line Connected to the Engine Return Line to Return Air & Vapor to the Tank! 6 Micron Particulate Filters Long Lasting MicroGlass Media Protective Wire Screen In Water Separator Nipple! Water Separator/Prefilter Long Lasting Wire Mesh Media All AirDog Products are Manufactured with Flash Proof Electrical Components! Approved for Use in California by CARB! 2
DEMAND FLOW FPII-200 SYSTEM OVERVIEW Welcome to the AirDog Fuel Preporator Fuel Air Separation System for Class 8 Trucks The AirDog, with ADVANCED FUEL AIR SEPARATION, DEMAND FLOW, ADJUSTABLE REGULATOR, MICROPROCESSOR FILTER MONITOR and the NEW 4G- HD FUEL PUMP, is a premium fuel filtration and delivery system for the N-14 Cummins Engine. Air & Vapor are compressible! When Air/Vapor is present in a fuel injection system the pressure buildup and injection of fuel is delayed while the Air/Vapor is being compressed. This delay retards the injection timing causing a shorter power stroke and low power, increased fuel consumption and increased exhaust emissions. Preventing the formation of vapor from pump cavitation and removing entrained air from the fuel flow to the injectors restores Correct Injection Timing. Diesel engines 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 air that becomes entrained in diesel fuel, from the fuel flow to your engine. The entrained air and vapor that is separated from the fuel is returned to the fuel tank through a small return line. The fuel flow to the engine s transfer pump is at a NET POSITIVE PRESSURE HEAD preventing cavitation and the formation of vapor thus overcoming the performance related problems from plugged fuel filters, high altitude operation and torque loss at higher engine RPM s. All AirDog products are manufactured with a personal touch, unsurpassed attention to detail and the most stringent quality assurance! CUMMINS N-14 INSTALLATION LAYOUT Air/Vapor Return to Tank Transfer Pump Engine ECM & Cooler Plate Fuel with Entrained Air AirDog FPII -200 Figure 1 The AirDog requires only one small return line connected to the engine return line for quick and easy installations. 3
Section 1 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......... AirDog & Mounting Brackets Section 6...N-14 Transfer Pump/Primary Fuel Filter Conversion. Fuel Lines, Fittings & Low Fuel Pressure Sensor Switch Section 7A...Fittings & Sensor Switch Section 7B..........AirDog Air/Vapor Return Line Section 7C.....Fuel Line from AirDog to Transfer Pump Section 7D........From ECM Cooler Plate to AirDog Electrical Harness Section 8............Electrical Harness Section 9............ Initial Start Up Maintenance Cummins N-14 w/pump Mount Filter Table of Contents Section 10........ Filter Service Recommendations Section 11...Cleaning the Gerotor Assembly Section 12...Pressure Regulator 4
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. Notify PureFlow Technologies, immediately of any parts missing or damaged. 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 fittings 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: CAUTION: CAUTION: Chock the vehicle s tires to prevent rolling. Disconnect the battery cables before proceeding with the AirDog installation. 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 flange 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 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. 5
Section 3 Cummins N-14 w/pump Mount Filter Installation Parts List QTY DESCRIPTION Part Number IMAGE 1 Installation Manual 206-1-0504 1 AirDog FPII-200 Parts List 2 Mounting Bracket 1 Hardware Kit, Includes: 4ea 3/8 x 1-1/2 Hex Head Bolt, 4ea 3/8 Nut 4ea 3/8 Lock Washer 4 Socket Head Cap Screws, 1/4-20 x 2" Lg. 4 Lock Washers, 1/4 4 Hex Nuts, 1/4-20 Wiring Harness with Microprocessor & 1 Indicator Light 6 002-3C-0003 002-3C-0004 901-08-0100 5E-2-3370-12 1 Fuel Pressure Sensor 5C-9-007 2 #10 - JIC Flare x 1/2 NPT Fitting 4A-1-01-10-08-B 2 #10-90 0 Swivel X JIC Flare Fitting 4A-2-04-10-10-S 1 #6 - JIC Flare x ¼ NPT Air/Vapor Return Fitting 4A-1-01-A-C-SZ Cummins N-14 Return Line Kit Components 1 #6 - JIC Flare x ¼ NPT Air/Vapor Return Fitting 4A-1-01-A-C-SZ 1 #8 - Female Swivel x #8 Male Flare x ¼ Side 4A-1-11-08-08-4P Port Return T 1 #6-90º Swivel x Fuel Line End 4A-2-13-05-06-S 1 #6 - Swivel x Straight Fuel Line End 4A-1-13-06-06-S 1 7 ft Section DOT Air/Vapor Return Line 4C-1-02-05-002-7 Cummins N-14 Conversion Kit for Pump Mount to Remote Mount Fuel Filter 1 #10 Line Kit - ECM Cooler to AirDog & Transfer Pump Include: 1-9 ft Section of #10 DOT Fuel Line 2 - #10-90 0 Swivel X Fuel Line End Fitting 2 - #10 - Swivel x Straight Fuel Line End Fitting 4C-1-10-10 4A-2-13-10-10-S 4A-1-13-10-10-S 1 1/2 ORB x #10 - JIC Flare Fitting 4A-1-02-10-08-S 1 Pulse Dampener with O-ring 1 Set of: 2 ea Socket Head Cap Screws ¼-20 x 3 2 ea 1/4 Lock Washers 002-4G-0008 4G-2-00001 1L-A48C 1R-9-AC
Section 4 Selecting the Best Mounting Location Selecting the Best Location to Mount The AirDog When possible, mount the AirDog in the same location of the original fuel filter. 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 filter 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! 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. Figure 2 shows the AirDog mounted on the frame under the steering column to the rear of the shock absorber. Figure 3, in a different truck, shows the AirDog mounted under the steering column ahead of the shock absorber. FIGURE 2 FIGURE 3 NOTE: When mounting the AirDog at this location, check for clearance with the tire turned both toward and away from the frame! 7
Section 4 Selecting the Best Mounting Location Selecting the Best Mounting Location, cont d This installation, on a short nose Day Cab, is on the driver s side, frame rail behind the battery box. FIGURE 4 Section 5: Mounting THE AIRDOG ON THE TRUCK S FRAME! 5-1. Disconnect the fuel lines and remove the primary fuel filter. FIGURE 5 FIGURE 6 NOTE: Mount the AirDog as close to the original location of the primary fuel filter as possible. This will allow you, in many cases, to use the original fuel supply line from the fuel tank and also the fuel line to the engine. 5-2. Hold the AirDog with the brackets and filters attached next to the frame at the selected location, check for clearance. FIGURE 7 FIGURE 8 5-3. Turn the steering wheel fully to the left and right to check for tire clearance. 8
Section 5 Mounting the AirDog MOUNTING THE AirDog ON THE TRUCK S FRAME Cont d! 5-4. Mark and center punch each hole location. FIGURE 9 FIGURE 10 5-5. Drill a 3/8 hole at each of the 4 previously marked locations. WARNING! DO NOT DRILL INTO OR DAMAGE ANY WIRING, AIR LINES OR OTHER COMPONENTS LOCATED BEHIND THE FRAME RAIL. 5-6. Loose assemble the mounting brackets to the frame. FIGURE 11 FIGURE 12 5-7. After mounting the AirDog on the brackets, snug the fasteners to achieve a good relaxed fit. Properly tighten all of the fasteners. NOTE: These steps are necessary to prevent stress cracks from forming in the mounting brackets due to vibration. Section 6: AirDog Pump Mount Fuel Filter Conversion! Primary Fuel Filters: It is most important that there are no fuel filters between the AirDog and the engine s transfer pump that could plug and cause restriction. These filters must be removed from the system as part of the AirDog installation. Figure 13 FROM THIS TO THIS 9
Section 6 Removing the Primary Fuel Filter Head Pump Mount Primary Fuel Filter Conversion, cont d! Before connecting the AirDog to your Cummins N-14 transfer pump, the primary fuel filter assembly mounted on the transfer pump should be removed. 6-1. Remove the 4 socket head cap screws securing the filter head to the transfer pump. Remove the primary fuel filter head from the transfer pump. Figure 14 Figure 15 6-2. Install the two (2) ¼-20 x 3 socket head cap screws and lock washers supplied in the kit. 6-3. Install the Pulse Dampener using the longer ¼-20 socket head cap screws and washers previously removed in step 6-1. Be careful to properly install the O-ring in the pulse dampener! Figure 16 Figure 17 6-4. Install the #10 JIC male flare x ¾ -16 UNF ORB fuel fitting in the fuel inlet port on the transfer pump. Properly tighten the socket head cap screws and fuel inlet fitting. Field Serviceable Hose End Assembly Instructions: 1. Lubricate insert threads and I.D. of hose. 2. Screw hose into socket (left-hand thread) until hose bottoms. Back out 1/4 turn. 3. Screw insert into socket until insert touches socket. 10
Section 7 Fuel Lines, Fittings, & Low Pressure Sensor FUEL LINE OVERVIEW The AirDog has been engineered to eliminate fuel related problems. It is important that the fuel lines are assembled and installed properly so as not to cause fuel flow restriction. When possible, use the fuel lines that are on the vehicle. This will reduce your installation costs and make the installation go much more quickly. NOTE: On various class 8 trucks, the manufacturer may use other than traditional steel braid fuel lines. These lines require special fittings. The fittings used with the original primary fuel filter are specific 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 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 exceed DOT requirements. Fuel Supply Line: The fuel supply lines from the tank to the AirDog and to the engine should be size 10 or, at the absolute minimum, size 8 (1/2 ID). Air/Vapor Return Line: The AirDog Air/Vapor return line can be connected to the engine s return line. A size 6 is adequate for the Air/Vapor return line. Primary Fuel Filters: It is most important that there are no fuel filters between the fuel tank and the AirDog or between the AirDog and the engine s transfer pump to plug and cause restriction. These filters should be removed from the system as part of the AirDog installation. Secondary Fuel Filters: DO NOT REMOVE SECONDARY FUEL FILTERS. This is the filter between the transfer pump and the engine. Section 7A: Fuel Fittings and Pressure Sensor Switch! IMPORTANT: Use diesel compatible thread sealer when installing NPT fittings. NOTE: Figures 18 & 19 illustrate the installation of straight fittings. However, in some instances a 90º fitting may be required to connect the fuel lines to the AirDog. A 90º swivel fitting have been included in the kit for this purpose. 7A-1. Install the straight #10 JIC x ½ NPT fuel fitting in the AirDog fuel marked ENGINE. Figure 18 Figure 19 7A-2. Install a straight #10 JIC x ½ NPT fuel fitting into the fuel inlet port next to the regulator. 11
AirDog FPII-200 Section 7 Fuel Lines Section 7A: Fuel Fittings and Pressure Sensor Switch, cont d! 7-3. Install the ¼ NPT x #6 JIC Male Air/Vapor return fitting into the Air/Vapor return port marked TANK. Figure 20 Figure 21 7A-4. Remove the 1/8 NPT plug from the end of the pre-installed 45 0 fitting in the AirDog base. Install the pressure sensor switch into the 45 0 fitting. SECTION 7B: Air/Vapor Return Line The AirDog returns entrained air & vapor to the fuel tank. The AirDog Air/Vapor return line may be connected directly to the engine fuel return line Low Pressure side after the regulator. NOTE: A #6 size line has a sufficient ID for the AirDog Air/Vapor return. Keep in mind that some trucks have a #6, low pressure side return line, while others have #8 low pressure side return line. The Installation Kit includes both size fittings for your convenience. 7B-1. Install the #6 JIC Male Flare x ¼ NPT fitting into the ¼ Female NPT port of the T. Figure 22 7B-2. Disconnect the engine fuel return line from the #8 JIC flare fitting located on the side of the engine. Figure 23 Engine Fuel Return Line Figure 24 7B-3. Screw the swivel end of the Air/Vapor return T onto the engine fuel return fitting. Attach the engine return line to the JIC Male Flare on the other end. 12
AirDog FPII-200 Section 7 Fuel Lines SECTION 7B: Air/Vapor Return Line, cont d! 7B-4. Measure and cut a length of fuel line necessary to reach from the AirDog Air/Vapor return fitting to the fuel return T. Figure 25 Figure 26 7B-5. Assemble the fuel line with the proper end fittings for the connections. Route and connect the Air/Vapor return line to the proper fittings on the AirDog and the return T. Properly tighten the fittings. Secure the fuel line as necessary to prevent abrasion and chaffing. SECTION 6C: Connecting the AirDog to the Engine Transfer Pump! 7C-1. Measure and cut a length of fuel line necessary to reach from the AirDog out to ENGINE port to the fuel inlet fitting on the transfer pump. Figure 27 Figure 28 NOTE: This assembled fuel line is for illustration only, use the proper end fittings that apply to your application! 7C-2. Assemble the fuel line with the proper end fittings. Figure 29 7C-3. Route and connect the fuel line to the proper fittings on the AirDog and the engine transfer pump. Properly tighten the fittings. Secure the fuel line as necessary to prevent abrasion and chaffing. NOTE: Use a 90 0 swivel fitting as necessary. Figure 30 13
Section 7 Fuel Lines SECTION 7D: Connecting the AirDog Fuel Supply Line to the ECM Cooler Plate! 7D-1. Measure and cut a length of fuel line necessary to reach from the AirDog FUEL IN port to the fuel outlet fitting on the ECM Cooler Plate. Figure 31 Figure 32 7D-2. Assemble the fuel line with the proper end fittings. 7D-3. Route and connect the fuel line to the proper fittings on the AirDog and the ECM Cooler Plate. Use a 90 0 swivel fitting as necessary! 7D-4. Properly tighten the fittings. Secure the fuel line as necessary to prevent abrasion and chaffing. VERY IMPORTANT: The N-14 ECM Cooler Plate has directional flow. There is a specific inlet and outlet port. Should the fuel lines be connected in reverse when installing the AirDog, a flow issue may develop that will cause the Indicator Light to come on when backing off the throttle while driving. Should this happen, simply connect the fuel lines going in and out of the ECM Cooler to the correct port. 14
Section 8 ELECTRICAL HARNESS The AirDog wiring harness has a Microprocessor and two color LED indicator light as standard equipment. VERY IMPORTANT: The LED Indicator Light will remain green until the first stage of filter plugging. It will then turn RED, indicating the fuel filter needs replacing. Then, if the filter is not timely changed, the light will begin flashing RED. Additionally, should pressure flow to the engine drop below minimum requirements, the light will immediately begin flashing GREEN. First check the water separator. Then, check the screen in the water separator nipple. Clean or replace as necessary. The AirDog Microprocessor wiring harness. AirDog Pump Motor Lead Pressure Sensor/Switch Lead Indicator Light & Lead Battery Positive Lead Battery Negative Lead Relay Lead Electrical Harness Figure 33 Securing the Microprocessor to the Vehicle 8-1. Secure the Microprocessor to the vehicle. This picture shows the Microprocessor mounted next to the steering column. Figure 34 Figure 35 8-2. Route the pump motor and indicator light sensor lead to the AirDog. Connect the 2 pin Deutsch connector on the end of the wiring harness to the pump motor lead. Figure 36 Figure 37 8-3. Connect the lead with the green seal to the sensor switch. 15
Section 8 Routing the Indicator Light Lead Electrical Harness The Low Fuel Pressure Indicator Light wiring leads must be routed through the firewall to Dash Board. 8-4. Peterbilts and Kenworths have access holes located below the steering column. Remove the plug and route the leads through the hole. Figure 38 Figure 39 8-5. For other make trucks, drill a 5/8" hole in firewall to allow entry of the Indicator Light Lead into the cab. By the Steering Column Under the Dash Figure 40 Figure 41 8-6. Route the indicator light lead through the firewall. Be sure to seal the opening or install a grommet around the wire loom to prevent water leakage and protect it from chaffing. NOTE: Be sure to seal the opening or install a grommet around the wire loom to prevent water leakage and for protection from chaffing. 16
Section 8 Electrical Harness INSTALLING THE FUEL FILTER INDICATOR LIGHT! Figure 42 8-7. Select a location on the dash board that is easily visible to the driver. Figure 43 Figure 44 8-8. Remove the dash components as necessary to access the area behind the selected location. 8-9. Drill a 9/16 hole in the dash at the selected location. Be very careful when drilling. Do not damage components located behind the dash. Figure 45 8-10. Assemble the Indicator Light in the dash. Connect the Indicator Light Lead to the connector on the wiring harness. 8-11. Re-install the removed dash components back to their original position. Figure 46 17
Section 8 Electrical Harness Connecting the Relay Trigger Lead! The Relay Trigger Lead must be connected to a contact point that is HOT when the starter key is in the ON position. This could be either in the engine compartment or inside the dash such as a spare fuse holder in the fuse panel or on the ignition switch itself. Note: DO NOT connect the relay lead to a point that is HOT when the starter key is in the ACCESSORY ON position. NOTE: For the Cummins N-14, the Fuel Shut-off Solenoid on the transfer pump is the ideal point to connect the Relay Trigger Lead. Figure 47 Figure 48 8-15. Connect the relay trigger lead to the fuel solenoid terminal. 8-16. If preferred, the relay trigger lead can be connected directly to the ON or RUN terminal on the ignition switch. Battery Figure 49 Ignition Accessory 18
Section 8 Electrical Harness CONNECTING THE POWER SUPPLY LEADS The power supply leads can be easily connected to the appropriate contacts on the alternator. However, any high amperage terminal that is always HOT is OK for the Positive + (RED) lead. Be sure the NEGATIVE (BLACK) lead is connected to a reliable Chassis Ground. 8-17. Route the Red & Black power supply leads to the alternator. Connect the Black (-) ground lead to the alternator Ground connection. Figure 50 Figure 51 8-18. Connect the Red (+) positive lead to the alternator Hot Lead going to the battery. SECTION 9: INITIAL START UP PROCEDURE The AirDog is a self priming system. However, to prevent damage to a dry seal and reduce the life expectancy of the system, pre-fill the water separator/pre-filter with diesel fuel UP TO THE BOTTOM OF THE NUT PLATE. 9-1. Pre-fill the water separator/pre-filter with diesel fuel up to the bottom of the nut plate. 9-2. Turn the starter key to the on/run position. 9-3. 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 purged of is 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 PROPERLY TORQUE. BE SURE ALL LINES ARE PROPERLY ROUTED TO PROTECT FROM EXCESSIVE HEAT AND SECURED TO PROTECT FROM CHAFFING AND ABRASION. RECHECK ALL ELECTRICAL LINES, SECURE AS NECESSARY. 9-4. Start your engine! 19
Section 10 Fuel Filter & Pre-Filter Servicing the AirDog Fuel Filter and Water Separator/Prefilter The AirDog Microprocessor monitors the fuel filter and water separator! FUEL FILTER: Plugging of the fuel filter will cause the AirDog Indicator Light to go from GREEN to RED. Failure to timely service the fuel filter will cause the light to change from RED to FLASHING RED. Replace the fuel filter as necessary! It is recommended to replace the fuel filter at 25,000 miles of service OR when the Indicator Light turns RED, which ever comes first! When replacing the fuel filter, be sure to clean the under side of the AirDog base. It is not necessary to pre-fill the fuel filter with fuel, the AirDog will fill the filter and prime the system automatically. Follow the instructions on the filter for proper tightening procedures. AirDog Fuel Filter Figure 52 The Water Separator/Pre-filter Pre-filter Nipple with Wire Screen Prefilter/Water Separator With Drain Valve WATER SEPARATOR: Should the water separator/pre-filter or the wire screen in the nipple become plugged, preventing sufficient operating pressure flow to the engine, the Indicator Light will immediately change from GREEN to FLASHING GREEN. Check the water separator/pre-filter for plugging. Clean or Replace as necessary! If the light continues to FLASH GREEN, 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 of the water separator simply requires draining at regular intervals. It is suggested to check/drain the water separator weekly or as needed should you experience excessive water in fuel conditions. Before re-installing the water separator after cleaning, be sure to clean the under side of the AirDog base. Follow the instructions printed on the water separator/pre-filter for proper tightening procedures. DO NOT over tighten and damage the water separator with a filter wrench. Caution: Be careful to prevent any contaminates or debris from entering the water separator when remove it for cleaning! Even though the water separator/pre-filter nipple has a protective wire screen, debris could jam the Gerotor and cause the fuse to blow. This is not a warranty item. Should this happen, it is easily put back into working order. See the instructions on How to R & R the Gerotor for proper cleaning procedures. Dispose of waste fuel and used filters properly to protect OUR environment! 20
Section 11 Gerotor & Pump Assembly Cleaning Debris from the Gerotor Assembly Step 1 Step 2 Step 3 Remove the four (4) socket Carefully remove the O-rings, Remove and clean the gerotor. head cap crews that secure you will need to re-use them. Be very careful not to damage the gerotor cap. the gerotor. Step 4 Step 5 Step 6 Remove the O-rings and clean Replace the center gear. Align and install the outer the inside of the gerotor pocket. gear and O-rings. Step 7 Step 8 1 4 3 2 Install the gerotor cap. Be very careful not to dislodge or pinch the O-rings. Loose assemble the cap screws. Torque the cap screws in an opposing pattern. NOTE: Should any installation problems arise, please call, toll free 1-877-463-4373 or - 1-573-635-0555, for assistance Monday Friday, 8:00 AM 4:30 PM CST. 21
Section 12 Pressure Regulator How to Remove and Re-install the Pressure Regulator! The Adjustable Pressure Regulator is made of all stainless steel components, except for the viton O rings. Regulator Components A - Adjustor Screw B - Jam Nut C - Base Nut Figure 53 D - Spring E - Plunger F - Plunger O ring F E D C A B STEP 1 STEP 2 STEP 3 Loosen Jam Nut B and regulator base nut C. Turn Adjustor Screw A Counter clockwise to remove the assembly. Remove the Adjustor Assembly from the AirDog base. Be careful to not damage the O rings or lose the regulator spring or plunger. STEP 4 STEP 5 STEP 6 Be sure the Regulator Plunger and Spring are properly positioned, then : carefully insert the Adjustor Assembly into the base. Turn the assembly clockwise until the base nut is flush with the surface of the AirDog base. Tighten the Base Nut. 22 Re-adjust the output pressure by turning the Adjustor Screw counter clockwise until it stops against the Base Nut. Then, turn the Adjustor Screw in, clockwise 5 full turns.
NOTES 23
Copyright 2012 Bulletin No. 206-1-0504 CD Patents, LLC Revised September, 2012 All Rights 24 Reserved