“spin-on” high pressure fuel air separator installation … · 2021. 3. 9. · mack® mp7, mp8,...

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

VOLVO® VED-12, D11, D12, D13, D13TC, D16, &MACK® MP7, MP8, MP8HE ENGINES

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 3/9/2021

PLEASE READ THESE INSTRUCTIONS

THOROUGHLY BEFORE BEGINNING

INSTALLATION

Part No. A7SOVM750

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The AirDog® Champ II™ is proudly made in the USA.

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® 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 InstallationSpins on between filter head and the fuel filter. 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.

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PureFlow® Technologies, Inc.AirDog® Champ II™ VOLVO® VED-12, D11, D12, D13, D16 & MACK® MP7, MP8

TABLE OF CONTENTSSection 1………….........…….…...………............…..…………..….Table of ContentsSection 2……………………..........…………………Installation and Safety GuidelinesSection 3……………………..........………………………………………..…Parts ListSection 4……………...........………...........................................….....System Overview

INSTALLATION PROCEDURESSection 5………………..........………………..............Installing the AirDog® Champ II™

Section 6………………………...............................Installing the Air/Vapor Return Line Section 7....………………..........................................…….....Initial Start-Up Procedure

MAINTENANCESection 8..…………………………....................................................……Filter Service

Section 1 Table of Contents

Section 2: 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 missing or damaged parts.

2. Read the installation manual completely. Understand how the system operates and the installation recommendations before beginning.

SAFETY GUIDELINESCAUTION: 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 harnessestopreventchafing.

If you are uncertain of any installation procedure, contactPureFlow® 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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1 3/8 Low Pressure Hose (Air/Vapor Return Line) - 4 ft 4C-1-02-05-010-4FT

Section 3 Parts List

Installation Parts List

Section 4: System OverviewPureFlow® 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.

QTY Description Part Number Image

1 Installation Manual 207-7-0750

1 AirDog® Champ II™ High Pressure Air Separator CHPII-750-WIP

1 Volvo® 28356886 Fuel Filter FF-23856886

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 #6M JIC x #6F JICX 90⁰ Street Elbow 4A-2-04-06-06-S

2 #6F JICX x 3/8 Push-lock Hose Barb 4A-1-09-06-06-B

1 Quick Connect Return Adapter Sub-Assy 908-VM-QCRA (1) Quick Connect Return Adapter 001-4A-1-0051 (1) 1/4 Hex w/ Vibraseal Pipe Plug 4A-3-01-A-S2 (1) 12.5 x 2.5 mm O-Ring 1U-2-1-12.5 (1) Quick Connect Retainer Clip 4C-2-00-00 (1) #6M JIC x 1/4 M NPTF 4A-1-01-A-C-SZ

970-07-0750 Installation Fitting Kit

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Install Fitting

Figure 4

Section 5 Installing the Champ II™

Section 5: Installing the AirDog® Champ II™

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. Install the Champ II™ onto the Volvo/Mack secondaryfuelfilterheadbyspinningituntiltheo-ringmakes contact, and the airbleed is in an easily accessible position. (Figure 3)

NOTE: The Champ II™ is a “spin-on” unit.

5-5.Holdair/vaporreturnfittingwitha9/16wrench.Thenusing a 1” wrench tighten the pick-up tube until the Champ II™ becomessnugagainstthefilter-head.(Figure 4)

5-4.Installthe3/8ORBx#6JIC90°elbowfittingintotheair/vaporreturn port. (Figure 3)

Figure 1

5-1. RemovetheVolvo/Macksecondaryfuelfilter.(Figure1)

Figure 3

Figure 2

NOTICE: FOLLOW THESE INSTRUCTIONS CLOSELY! OVER-

TIGHTENING COULD BREAK THE OE SECONDARY FILTER HOUSING.

DO NOT OVER-TIGHTEN!

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Section 6 Air/Vapor Return Lines

Air/Vapor Return Tee on the Volvo/Mack

6-1.OntheolderVolvo/Macktrucksthereturnlinesarelocatedontopofthefuelfilterhousing,andwillbe the smaller of the two fuel lines (3/8). On the newer Volvo/Mack trucks the return fuel lines are locat-edunderneaththerearofthefuelfilterhousing,andwillbethesmallerofthetwofuellines(3/8).

6-2. Remove the factory quick connect fuel line, and install the provided quick connect return adapter intothefactoryfitting.Be sure to lubricate the o-ring on the adapter and ensure the fitting is fully seated.Thensecurethefittingwiththeprovidedretainerclip.Installfactoryfuellineintothefemalesideofquickconnectreturnfitting.Oncelineisfullyseated,securewithfactoryretainerclip.

NOTE: Use diesel compatable thread sealer when installing NPT fittings.

Section 6: Installing the Champ II™ Air/Vapor Return LineThe 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.

Use included #6 JIC x #6 JICX

90°elbowfittingif needed.

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Section 7: Initial Start-Up ProcedureBesurethesecondaryfuelfilterispre-filledwithCLEAN diesel fuel TO THE BOTTOM OF THE “NUT PLATE”.

r8-1.RubCLEANdieselfueloroilonfiltersealsbeforeinstallingtoensureaproperseal.

r8-2.Pre-fillthefuelfilterwithdieselfueltothebottomofthenutplateandinstallthefilter.

r 8-3. Start your engine.

r 8-4. Bleed the fuel line to the engine by slightly loosening the fuel line connection at the engine fitting.Assoonasthelineispurgedofair,tightenthefuelfitting.

NOTE:Putaragorshoptoweloverandaroundthefittingtopreventfuelsplatterorspray.Catchall 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

6-3A. For units already equipped with the AirDog® fuel filtration system, simply remove the existing 1/4 hex pipe plug from the quick connect return adapter. Install the #6 JIC x 1/4 NPTair/vaporreturnfittingintothequickcon-nect return adapter. Measure and cut provided return hose. Install #6 F JIC x 3/8 Push-Lock Hose Barbs on each end. Attach one end to quick connectreturnfitting.RoutereturnhosetotheChamp II™ and connect to the air/vapor return fitting.

6-3B. For units only utilizing the Champ II™ fuel filtration system, measure and cut provided return hose. Install #6 F JIC x 3/8 Push-Lock Hose Barbs on each end. Attach one end to quick connectreturnfitting.RoutereturnhosetotheChamp II™ and connect to the air/vapor return fitting.

Section 6: Installing the Champ II™ Air/Vapor Return Line, cont’d.

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Section 9 Filter Service

Section 8: Servicing the AirDog® Champ™ II Fuel FilterReplacethefuelfilterasrecommendedbyVOLVO®.

Whenreplacingthefuelfilter,besuretocleantheundersideoftheAirDog® Champ II™ base. Followtheinstructionsonthefilterforpropertighteningprocedures.

NOTE: Due to the fact that fuel filters are often OVER TIGHTENED and difficult to remove, it is suggested to use a 9/16 wrench on the 90° elbow fitting to use as a backup when changing the fuel filter.

Dispose of waste fuel and used filters properly to protect our environment.

AirDog® Champ II™ uses the VOLVO® High

Efficiency Fuel Filter

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NOTES

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NOTES

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NOTES

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Bulletin No. 207-7-0730BRevised August, 2017

Copyright© 2016CD Patents, LLC

All Rights Reserved

Copyright© 2016CD Patents, LLC

All Rights Reserved

Bulletin No. 207-7-0750Revised March 9, 2021

“spin-on” high pressure fuel air separator installation … · 2021. 3. 9. · mack® mp7, mp8,...

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