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 For PACCAR MX13 Diesel Engines Kit No. A6HSPA680 Providing “Test Cell Performance” in “Real World Conditions” Since 1993! Proudly Made in the USA www.pureflowtechnologies.com 1-573-635-0555 or 1-877-463-4373 Champ I High Pressure Fuel Air Separator with Positive Fuel Air Separation System PLEASE READ THESE INSTRUCTIONS THOROUGHLY BEFORE BEGINNING INSTALLATION Revised 2/2717
Transcript
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
For PACCAR MX13 Diesel Engines
Kit No. A6HSPA680
Providing “Test Cell Performance” in “Real World Conditions” Since 1993!
Amazingly Simple InstallationMounts on frame and connects between the engine transfer (fuel) pump and engine. Air/Vapor return line connects to engine fuel return line.
Amazingly Simple OperationOperates 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!
The Champ removes entrained air and vapor from the fuel flowing into the engine. Diesel engines equipped with the Champ can now perform as designed even under extreme operating conditions!
™
with PureFlow!Reach your
The Airdog® Champ is proudly made in the USA and features
a 4 year limited warranty.s Improves Fuel Mileages Lengthens Injector Life
s Smoother Idles Improves Throttle Response
s Maximizes Torques Reduces Emissions
Proudly made in the USA
With Pureflow Technologies AirDog® system installed your diesel engine can perform as designed even under the most extreme conditions.
Section 5………………………............………………..............Mounting the AirDog®
Fuel Lines, Fittings & Fuel Line Up-Grade
Section 6A……..…...………................... Fuel Line From the Fuel Pump to the Champ and Secondary Fuel Filter
Section 6B…..…….....…….....………………............………Air Vapor Return to Tank
Maintenance
Section 7...….….....…..............…..……..................…Filter Service Recommendations
Section 1 Table of Contents
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PureFlow® Technologies, Inc.AirDog® Champ I PACCAR MX13
INSTALLATION GUIDELINESThe 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 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® Champ 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.
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: Do Not drill into or weld the top of the frame rail or within 1 ½” of the frame rail flangeonthesideoftheframerail.
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 harnessestopreventchaffing.
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.
Section 2 Installation & Safety Guidelines
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PureFlow® Technologies, Inc.AirDog® Champ I PACCAR MX13
Installation Parts ListSection 3 Parts ListQTY Description Part Number Image
1 Installation Manual 206-6-0680
1 AirDog® Champ I High Pressure Air Separator HPAS-585
1 Sandwich Mounting Bracket Kit for AirDog® & Champ 002-3C-0010-SBF Includes: 1 Front & 1 Back 002-3C-0011-SBB Center Bracket 002-3C-0006PCB
2 #8 - JIC Flare x 1/2” ORB Fitting 4A-1-02-08-08-S
1 Push-In x 3/8 Female NPT Fitting w/O’ring 006-00-PA-001
1 #8 - JIC Flare x 16mm ORB Fitting 4A-1-01-08-16-S 16mm O’ring with Steel Retainer Ring 1P-5-FS
1 Clamp, Paccar (plastic) 4C-2-00-00
1 3/8” NPT Elbow 006-00-PA-002
1 #8 Male JIC x 3/8” Female NPT 4A-2-02-06-08-S
3 O’ring, 12.5 x 2.5 mm (Paccar Champ fitting kit) 1U-2-1-12.5
960-06-0680 Paccar Fitting Kit
901-08-0100
901-08-0100-SB
2 Mounting Bracket 002-3C-0003 002-3C-0004
1 Hardware Kit, Includes: 3 ea 3/8”-16 x 3-1/2” Hex Head Bolt 1J-1-C56SZ 7 ea 3/8” Nut 1S-1-CSZ 7 ea 3/8” Lock Washer 1R-6-CSZ 4 Screw, 3/8-16x1” F/H SHCS 1M-C16SZ
1 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 Socket Head Cap Screws, 1/4-20 x 2” Lg 1L-A32C 4 Lock Washers, 1/4” 1R-6-AC 4 Hex Nuts, 1/4-20 1S-1-AC
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PureFlow® Technologies, Inc.AirDog® Champ I PACCAR MX13Section 4 System Overview
Champ ISECTION 4: SYSTEM OVERVIEW
Welcome to the “AirDog® Champ”High Pressure Fuel Air Separation System for Class 8 Trucks
The AirDog®, Champ with ADVANCED FUEL AIR SEPARATION is a premium fuel air separator for Paccar MX13 Engine.
The AirDog® Champ is installed between the engine transfer pump or secondary fuel filter housing, removing virtually all entrained air and vapor from the fuel flow to the engine.
TYPICAL INSTALLATION LAYOUT
Fuel Line fromChamp to Engine
Air/Vapor Return LineConnects to engine return line.
Fuel Line from Engine Transfer Pump to Champ
AirDog® Champ I
Figure 1
IMPORTANT: The AirDog® Champ requires only one small return line connected to the low pressure side of the engine return line for quick & easy installations.
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PureFlow® Technologies, Inc.AirDog® Champ I PACCAR MX13Section 5 Mounting the AirDog® Champ I
Selecting the Best Location to Mount the AirDog® Champ!Installing the AirDog® Champ at the proper location on the vehicle is most important. When deciding where to locate the AirDog®, the following points should be considered:
• Bestrelationshiptothesecondaryfuelfilterandbackofenginehead.• Protectionfromtheelementsandroaddebris.• Accessibility for service.
Figures 2 and 3 depicts the AirDog® Champ mounted on the frame. There are many variations in the arrangements of the components on the various trucks. With a little ingenuity, the AirDog® Champ can be easily installed on any Class 8 Truck.
Figure 2
Figure 3
5-1. Hold the AirDog®Champ,withthebracketsandfilterattached,nexttotheframe attheselected 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.
Figure 4
Figure 55-2. Mark and center punch the hole locations. Drill a 3/8” hole at each of the 4 locations and attach the AirDog® Champ brackets
WARNING! DO NOT DRILL INTO OR DAMAGE ANY WIRING, AIR LINES OR OTHER COMPONENTS LOCATED BEHIND THE FRAME RAIL.
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PureFlow® Technologies, Inc.AirDog® Champ I PACCAR MX13Section 5 Mounting the AirDog® Champ I
Mounting the AirDog® on the Truck’s Frame, cont’d!5-3. In this installation, the spring shackle bracket is in the way. Using PureFlow Technologies Universal Mounting Bracket & spacers easily overcomes this obstacle!
Figure 6
Figure 7
5-4. Mark and center punch the selected hole locations. Drill the holes and attach the universal mounting bracket. Attach the AirDog® Champ brackets to the “Universal Bracket”.
5-5. With the brackets well secured to the truck’s frame, be sure the AirDog® Champ is securely attached to the brackets.
A CB
Section 6A: Fuel Lines From Transfer Pump to AirDog® Champ
6A-1. InstallfittingsA. “Fuel In”, B. “Air Return” and C. “Fuel Out”, in the AirDog® Champ.
6A-2. Remove 16mm “Banjo Bolt” and fuel line from the fuel inlet port on the side of the transfer pump.
6A-3. Followthefuelline(Fig.12)tothesecondaryfuelfilterhousingabovethetransferpump.Remove the “Retainer Clip” holding the fuel line “Quick Connect Fitting”, then remove the molded fuelline(Fig.11)fromthesecondaryfuelfilterhousing.
Fuel Lines From Transfer Pump to AirDog® Champ cont’d6A-4. Assemblethe3/8”MaleNPTX#8JICfittingintotheAirDog® “Paccar Quick Connect” Fitting. Use diesel compatible thread sealer. Remove the “Paccar Retainer Clip” from the molded fuel line and plastic tieittothenew“quickconnect”fittingassembly.
6A-5. Installthe16mmORBX#8JICfittingwithsteelretainerO’ringinthe “Fuel Out” port on the transfer pump just vacated by the banjo bolt.
6A-6. Install the AirDog®Champ“QuickConnect”fittingassemblyintothesecondaryfilterhousing.
6A-10. Route and connect the new fuel line (shown in black with white dots) to the #8 “Fuel Out” fittinginthefuelpumpandthentothe“fuelin”fittingintheChamp.Properlysecure.
Section 6B: Air Vapor Return to Tank6B-1. RemovethePaccarfuelreturnlineandquickconnectfittingfromthefuelmanifoldontheengine.
6B-2. Assemble and install the AirDog® Champ Special Return “T” in the fuel return port of the fuelmanifold.InstallthePaccarQuickConnectfittingintheChampreturn“T”.
6B-3. Re-connect the Paccar fuel return line.
6B-4. Measure, cut, and assemble a #6 Air/Vapor return line to connect the Champ Air/Vapor return port to the Special Return “T”.
6B-5. Install the new #6 Air/Vapor return line shown in Blue with white dots.
Note: Secure all fuel lines to prevent damage from abrasion.
Figure 16
Figure 17
Figure 18
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PureFlow® Technologies, Inc.AirDog® Champ I PACCAR MX13Section 7 Filter Service
Servicing the AirDog® Champ Fuel FilterItisrecommendedtoreplacethefuelfilterat25,000milesofserviceorasexperiencedictates.
