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INSTALLATION MANUALFor CUMMINS® N-14 ENGINES

Kit No. A6HSCU610

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 System

PLEASE READTHESE INSTRUCTIONS

THOROUGHLYBEFORE BEGINNING

INSTALLATION

Revised 2/27/17

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® N-14

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…………………...........……......................From Transfer Pump to Champ

From Champ To Fuel BlockSection 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 Cummins® N-14

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

5

PureFlow® Technologies, Inc.AirDog® Champ I Cummins® N-14

Installation Parts ListSection 3 Parts List

QTY Description Part Number Image

1 Installation Manual 206-6-0610

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

1 #6 JIC Flare x 1/4” NPT Air/Vapor Return Fitting 4A-1-01-A-C-SZ

1 #8 - Swivel x #8 Male Flare x 1/4” Return “T” 4A-1-11-08-08-4P

2 #6 JIC Flare x 1/2” ORB Fitting 4A-1-02-06-08-S

1 #6 JIC Male Straight x 1/2” - 20 Inverted Flare 4A-1-07-06-20-S

1 #5 - ORB Male to #6 JIC Male Adapter 4A-1-25-05-06-S

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

960-06-0610 Cummins Fitting Kit

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

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

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

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PureFlow® Technologies, Inc.AirDog® Champ I Cummins® N-14Section 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® N-14 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® N-14 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.

Fuel with No Air/Vapor to Engine

Fuel Distribution Block to Head Air/Vapor Return Line

Connects to engine return line.

Engine Fuel Pump Fuel Inlet For Fuel Supply From Tank

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PureFlow® Technologies, Inc.AirDog® Champ I Cummins® N-14Section 5 Mounting the AirDog® Champ I

Mounting the AirDog® on the Truck’s Frame!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 Cummins® N-14Section 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”.

Figure 8

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PureFlow® Technologies, Inc.AirDog® Champ I Cummins® N-14

A CB

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

Fuel Supply Line: The fuel supply lines from the transfer pump to the AirDog® Champ and to the engine should be size 6.

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.“Air Return” and C. “Fuel Out”, in the AirDog® Champ.

Figure 9

6A-2. Disconnect and remove the fuel line connecting the transfer pump solenoid to the fuel block (Fig. 10).

Figure 10 Figure 11

Figure 12

6A-3. Install the # 5 ORB X #6 JIC in the fuel solenoid (Fig. 11).

6A-4. Install the Inverted Flare X #6 JIC in the fuel block (Fig. 12)

6A-5. Measure, cut, and assemble 2 NEW #6 fuel lines to connect the engine transfer pump to the Champ and the Champ to the Fuel Block.

Figure 13 Figure 14 Figure 15

6A-6. Connect a new #6 fuel line to the fuel transfer pump and to the AirDog® Champ “Fuel In” port (Fig. 13/14).

6A-7. Connect a new #6 fuel line to connect the Champ “Fuel Out” port Fig. 14 to the Fuel Block, (Fig. 15).

Disconnect fuel line here and here.

Route fuel linefrom here to here! Route fuel line

from here to here!

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PureFlow® Technologies, Inc.AirDog® Champ I Cummins® N-14Section 6 Fuel Lines & Fittings

Section 6B: Air Vapor Return to Tank6B-1. DisconnecttheENGINEfuelreturnlinefromthe#8JICfittingonthesideoftheengine.

Figure 16

Figure 17

Figure 18

6B-2. Assemble the AirDog® Champ Special Return “T”, Fig. 17, and install it on the engine fuel returnfitting.Reconnecttheenginereturnlinetothereturn“T”.

Figure 19

6B-3. Measure, cut, and assemble a #6 Air/Vapor return line and connect the Champ Air/Vapor return port to the Special Return “T” just installed.

Be sure to check the fuel rail pressure. Adjust as necessary!

Figure 21

Recommended Fuel Rail Pressure Specs taken from Cummins Service Manual

RPM GPH Fuel Rail Pressure1,200 74.25 130-1602,100 92.8 150-180

Connect Pressure Gauge Here!

Figure 20

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PureFlow® Technologies, Inc.AirDog® Champ I Cummins® N-14Section 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 22

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

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PureFlow® Technologies, Inc.AirDog® Champ I Cummins® N-14

Bulletin No. 206-6-0610Revised February, 2017

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All Rights Reserved