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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 MANUALFor CUMMINS® ISX15 ENGINES

Kit No. A6HSCU615

Providing “Test Cell Performance” in “Real World Conditions” Since 1993!

Proudly Made in the USA

www.pureflowtechnologies.com 1-573-635-0555or 1-877-463-4373

Champ IHigh Pressure Fuel Air Separator

with Positive Fuel Air Separation System

Revised 2/27/17

PLEASE READTHESE INSTRUCTIONS

THOROUGHLYBEFORE BEGINNING

INSTALLATION

2

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.

877-GO-DIESEL (877-463-4373) pureflowtechnologies.com

3

PureFlow® Technologies, Inc.AirDog® Champ I Cummins® ISX-15

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

INSTALLATION PROCEDURESSection 5………………………............………………..............Mounting the AirDog®

Fuel Lines & Fittings Section 6A…………………...........……...............Installing the Fuel Lines and FittingsSection 6B………………………...………...........................Air/Vapor Return to Tank

Maintenance

Section 7………………………….......................……Filter Service Recommendations

Section 1 Table of Contents

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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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Installation Parts ListSection 3 Parts List

QTY Description Part Number Image

1 Installation Manual 206-6-0615

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 Mounting Bracket 002-3C-0003 002-3C-0004

901-08-0100 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

2 # 8 Male JIC to 14mm Male Straight Metric 4A-1-01-08-14-S

1 16 mm Male ORB x 16 mm Female ORB x 908-09-0100-M #6 JIC Air/Vapor Return Fitting (Available only from PureFlow Technologies)

2 # 6 JIC Female Swivel x 3/8” Pushlock Hose Barb 4A-1-09-06-06-SZ

1 #6 Swivel x #6 JIC Forged 90° 4A-2-04-06-06-S

960-06-0615 Cummins ISX15 Fitting Kit

2 #8 - JIC Flare x 1/2” ORB Fitting 4A-1-02-08-08-S

1 #6 - JIC Flare x 9/16”-18 ORB Return Fitting 4A-1-01-06-06-S

960-06-0560 Basic Champ Fitting Kit

901-08-0100-SB 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

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PureFlow® Technologies, Inc.AirDog® Champ I Cummins® ISX-15Section 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 the Cummins® ISX-15 Engine.

The AirDog® Champ is installed between the engine transfer pump and the engine fuel rail, to remove virtually all entrained air and vapor from the fuel flow to the engine.

TYPICAL Cummins® ISX-15 Installation Layout

Figure 1

IMPORTANT: The AirDog® Champ requires only one small return line connected to the engine return line, for quick and easy installations.

Air/Vapor Return Line

Connects to engine return line.

Fuel In From Engine

Fuel with No Air/Vapor to

Engine

Fuel with No Air/Vapor to

Engine

Fuel In From Engine

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Mounting the Champ® to the Frame without Drilling!

Bracket 1 Bracket 3

Bracket 2

Mounting Hardware

Product Mounting Hardware

Bracket Bolts

Determine which holes in bracket 1 that you are going to need by holding it up to the frame of your vehicle.

Use mounting hardware to mount bracket 1 to bracket 2. The position of bracket 2 can be adjusted vertically and horizontally to suit your particular needs.

Using product mounting hardware, mount product to brackets.

Install 2 of the frame bracket bolts in top of bracket 1 & bracket 3. Slide over frame and install bottom bolt.

Tighten bolts as needed. Installfilterorfilterandwaterseparator as needed.

Any combination will work

Section 5 Mounting the AirDog® Champ I

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PureFlow® Technologies, Inc.AirDog® Champ I Cummins® ISX-15Section 5 Mounting the AirDog® Champ I

Mounting the Champ® to the Frame by Drilling!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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A CB

Section 6 Fuel Lines & FittingsInstalling the Fuel Lines and Fittings!

Fuel Supply Line: The fuel supply lines from the transfer pump to the AirDog® Champ and to the engine should be size 8.

Air/Vapor Return Line: The AirDog® Champ return line should be connected to the engine’s return line, low pressure side. A size 6 line for the Air/Vapor return line is adequate.

Fuel Line From Transfer Pump to AirDog® Champ

6A-1. InstallfittingsA.“FuelIn”,B.“AirReturn”andC.“FuelOut”, Figure 6in the AirDog® Champ. (Fig. 6)

6A-2. Disconnectandremovethefuellineconnectingthehighpressurepumptothefuelfilterbase.(Fig. 7).

Figure 7

Figure 8

6A-3. Install the # 8 Male JIC to 14mm Male Straight Metric in thefuelfilterbase.(Fig.8/9).

6A-4. Install the # 8 Male JIC to 14mm Male Straight Metric in the high pressure pump (Fig. 10)

6A-5. Measure, cut, and assemble 2 NEW #8 fuel lines to connect thefuelfilterbasetotheChampandtheChamptothehighpressure pump.

6A-6. Connect a new #8 fuel linetothefuelfilterbasetothe AirDog® Champ “Fuel In” port (Fig. 12/13). {GREEN}

6A-7. Connect a new #8 fuel line to connect the Champ “Fuel Out” port to the high pressure pump. (Fig. 11/12). {BLUE}

Figure 9

Figure 10

To “Fuel Out” on Champ

“Fuel Out”

“Fuel In”To “Fuel In” on Champ

Figure 11Figure 12

Figure 13

Disconnect fuel line here and here.

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PureFlow® Technologies, Inc.AirDog® Champ I Cummins® ISX-15Section 6 Fuel Lines & Fittings

Section 6B: Air Vapor Return to Tank6B-1. Disconnect the ENGINE fuel return line from the #8 JIC fittingonthesideoftheengine.(Fig.14)

6B-2. Install the AirDog® Champ Special Return Fitting. (Fig. 15)

6B-3. Measure, cut, and assemble a #6 Air/Vapor return line (Fig. 16) and connect the Champ Air/Vapor return port to the Special Return Fitting just installed. (Fig. 17)

Figure 14

Figure 15

Figure 17

Assembly Instruction for Hose Barb1. Cut hose line to length.2.Applyoiltofitting.3.Pushfittingintolineuntilseated.

Figure 16

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PureFlow® Technologies, Inc.AirDog® Champ I Cummins® ISX-15Section 7 Filter Service

Servicing the AirDog® Champ Fuel FilterItisrecommendedtoreplacethefuelfilterat25,000milesofserviceorasexperiencedictates.

Whenreplacingthefuelfilter,besuretocleantheundersideoftheAirDog® Champ base. Follow theinstructionsonthefilterforpropertighteningprocedures.

AirDog® ChampFuel Filter

6 Micron Micro Glass

Built in Check Valve Prevents fuel from

draining from the enginehead during filter changes.

Figure 18

Dispose of waste fuel and used filters properly to protect OUR environment!

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