industrial

The Original Fuel Air Separation System

INSTALLATION MANUAL
For Trucks Equipped with
CATERPILLAR 3406 A, B, or C Engines

PLEASE READ
THESE INSTRUCTIONS
THOROUGHLY
BEFORE BEGINNING
Kit No. A3SPBT401 INSTALLATION

NOW WITH DEMAND FLOW

Providing Test Cell Performance in Real World Conditions Since 1993!

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!
 industrial
THE RIGHT CHOICE FOR YOUR DIESEL ENGINE!
New Design 4G-HD Fuel Pump (4th generation)
Pump Shaft, stabilized with bearings on each end, holds the
Gerotor in virtually perfect alignment for quiet running and
extended longevity! Bearing

NewMicroProcessor NewQuickChange
FuelFilterMonitor Motor
If necessary, the motor can be
Letsyouknowwhento
removedandreplacedinamatter
ServicetheFuelFilter&
WaterSeparatorbefore
sufferingpowerloss

DualPortPump
BalancestheGerotor
forQuietOperation
and Higher Flows!
PositiveAirSeparation
WithPrimaryAirDischarge
Port

AdjustableRegulator
DemandFlowSystem! For Just the Right Fuel
Easy Installation, Only One
Small Line Connected to the
Engine Return Line to Return ProtectiveWireScreen
Ai / V t th T k! InWaterSeparatorNipple!

6MicronParticulateFilters WaterSeparator/Prefilter
LongLastingMicroGlassMedia LongLastingWireMesh
CARB Executive Orders No. D-595-1 & D-595U-1, permit the advertisement, sales, and
Media
installation in California of AirDog, AirDogII, Fuel Preporator, and Fuel PreporatorII

FPII150&FPII2008WX37/8DX12T FPII1257WX3DX10 T

2
 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 3406 A, B, or
C model CATERPILLAR 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 engines 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 RPMs.
All AirDog products are manufactured with a personal touch,
unsurpassed attention to detail
and
the most stringent quality assurance!
TYPICAL INSTALLATION LAYOUT

Figure 1
The AirDog requires only one small return line connected to the engine return line, for
quick and easy installations.
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 PureFlow Technologies, Inc.
AirDog FPII-150 CATERPILLAR 3406 A, B, & C
Section 1 Table of Contents

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
Fuel Lines,Fittings & Fuel Pressure Sensor Switch
Section 6A....Fittings & Sensor Switch
Section 6B.......Fuel Line from AirDog to Engine
Section 6C.....AirDog Air/Vapor Return to Tank
Section 6D......From Tank to AirDog
Section 7.....Secondary Fuel Filter Modification
Electrical System, Microprocessor Filter Monitor
VERY IMPORTANT: The AirDog electrical harness requires a MAXIMUM
15 Amp Fuse!
Section 8.....Electrical Harness Installation
Section 9....Initial Start Up
INSTALLATION PROCEDURES
Section 10.........Filter Service Recommendations
Section 11....Cleaning the Gerotor Assembly
Section 12........Pressure Regulator

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 PureFlow Technologies, Inc.
AirDog FPII-150 CATERPILLAR 3406 A, B, & C
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: Chock the vehicles tires to prevent rolling.

CAUTION: Disconnect the battery cables before proceeding with the AirDog
installation.
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 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.

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 PureFlow Technologies, Inc.
AirDog FPII-150 CATERPILLAR 3406 A, B, & C
Section 3 Parts List

Installation Parts List

QTY DESCRIPTION Part Number IMAGE
1 Installation Manual 206-1-0401

1 AirDog FPII-150

002-3C-0003
2 Mounting Bracket
002-3C-0004
1 Hardware Kit, Includes:
4ea 3/8 x 1-1/2 Hex Head Bolt,
4ea 3/8 Nut 901-08-0100
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

1 Wiring Harness with Microprocessor & 5E-2-3370-12

Indicator Light and Dash Plate Plus Grommet 201-3-0004
5J-1-1-04-2758

1 Fuel Pressure Sensor 5C-9-007

2 #10 Straight JIC Flare x 1/2 NPT Fitting 4A-1-01-10-08-B
2 #10 900 Swivel X JIC Flare Fitting 4A-2-04-10-10-S
1 #6 JIC Flare x NPT Return Fitting 4A-1-01-A-C-SZ

Caterpillar 3406A, B, & C Return Line Kit Components
1 #6 Return T 4A-4-04-06-06-06-4-S
1 #6 - 90 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

1 Hand Primer Pump Replacement Kit

002-4G-0006
Includes: 1 - Cap 002-4G-0007
1 - Gasket
PLEASE NOTE
Due to the many variables in components and arrangement of those components in the
many different truck models, the installation kit contains only the mounting brackets,
mounting hardware, wiring harness and basic fuel fittings needed to install the AirDog.

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 PureFlow Technologies, Inc.
AirDog FPII-150 CATERPILLAR 3406 A, B, & C
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!
Figures 2 thru 4 show examples of different AirDog installations. 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

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 PureFlow Technologies, Inc.
AirDog FPII-150 CATERPILLAR 3406 A, B, & C
Section 4 Selecting the Best Mounting Location

Selecting the Best Mounting Location, contd

This installation on a short nose

Day Cab is on the drivers side,
behind the battery box.

FIGURE 4

Section 5: MOUNTING THE AirDog ON THE TRUCKS FRAME!

5-1. Disconnect the fuel lines and remove the primary fuel filter.

FIGURE 5

FIGURE 6

5-2. Mount the AirDog as close to the original location of the primary fuel filter as
possible. This will allow you, in most cases, to use the original fuel supply line
from the fuel tank and also the fuel line to the engine.
NOTE: Mount the AirDog on the truck frame. DO NOT mount the AirDog on the
engine! Mounting the AirDog on the engine will immediately void your AirDog
warranty.
Secondary
Fuel Filter Primary
Fuel Filter

FIGURE 7

Transfer
Pump Injector Pump
1985 3406 B Caterpillar Engine

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 PureFlow Technologies, Inc.
AirDog FPII-150 CATERPILLAR 3406 A, B, & C
Section 5 Mounting the AirDog

MOUNTING THE AirDog ON THE TRUCKS FRAME!

5-3. Loose assemble the mounting brackets and filters to the AirDog.
5-4. Hold the AirDog, with the brackets and filters attached, next to the frame at the
selected 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 8 FIGURE 9
5-5. While holding the AirDog at the selected mounting location on the frame, mark
and center punch each hole location.
WARNING! DO NOT DRILL INTO OR DAMAGE ANY WIRING, AIR LINES OR
OTHER COMPONENTS LOCATED BEHIND THE FRAME RAIL.
5-6. Drill a 3/8 hole at each of the 4 previously marked locations.

FIGURE 10

FIGURE 11

5-7. Loose assemble the mounting brackets to the frame.

5-8. Loose assemble the AirDog

on the brackets.

Figure 12

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 PureFlow Technologies, Inc.
AirDog FPII-150 CATERPILLAR 3406 A, B, & C
Section 5 Mounting the AirDog

5-9. After mounting the AirDog on the

brackets, snug the fasteners to achieve a
good relaxed fit.
5-10. Properly tighten all of the fasteners.

NOTE: These steps are necessary to prevent

stress cracks from forming in the mounting
brackets due to road vibration and bouncing.
Figure 13

Section 6 Fuel Lines

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 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 engines 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 engines 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.

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 PureFlow Technologies, Inc.
AirDog FPII-150 CATERPILLAR 3406 A, B, & C
Section 6 Fuel Lines
Installing the Fuel Fittings and Pressure Sensor Switch!
IMPORTANT: Use diesel compatible thread sealer when installing NPT fittings.
NOTE: Figures 14 & 15 illustrate the installation of straight fittings. However, in some
instances 90 fittings may be required to connect the fuel lines to the AirDog.
Two 90 fittings have been included in the kit for this purpose.
6A-1. Install the straight #10 JIC x NPT fuel fitting in the AirDog fuel port marked
ENGINE. Use a 90 swivel fitting as needed when connecting the fuel line.

Figure 14

Figure 15
6A-2. Install a straight #10 JIC x NPT fuel fitting into the fuel inlet port next to the
regulator. Use a 90 swivel fitting as needed when connecting the fuel line.
6A-3. Install the NPT x #6 JIC Male return fitting into the Air/Vapor return port
marked TANK.

Figure 16

Figure 17

6A-4. Remove the 1/8 NPT plug from the end of the pre-installed 450 fitting in the
AirDog base. Install the pressure sensor switch into the 450 fitting.
Use diesel compatible thread sealer on all NPT threads!
Section 6B: Connecting the AirDog to the Transfer Pump on
the Engine!
6B-1. Connect the fuel line that originally connected the primary fuel filter (See Step 5-
1) to the transfer pump to the AirDog out to Engine port. If the fuel line is not
in good enough condition or the proper length to make the connection, replace it
with a new fuel line!

Figure 18

Figure 19
3406B Plunger Type 11
Transfer Pump
 PureFlow Technologies, Inc.
AirDog FPII-150 CATERPILLAR 3406 A, B, & C
Section 6 Fuel Lines

SECTION 6C: Installing the AirDog Return Line

The AirDog air/vapor return line may be connected directly to the injector pump fuel
return line The AirDog requires only one small return line making the installation quick
and easy!
NOTE: It is recommended to use a # 6 size line for the Air/Vapor return.
Connecting the AirDog Air/Vapor return to the engine fuel return line!
6C-1. Disconnect the fuel return line connected to the top of the injector pump and
install the T included in the installation.
Fuel Return Line

Figure 20 Figure 21

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.

6C-2. Measure and cut the length of fuel line required, when properly routed, to
connect the AirDog Air/Vapor return port to the new return T installed on the
injector pump. Assemble the fuel return line end fittings per standard procedures.

Figure 22

Figure 23

6C-3. Route and connect the new Air/Vapor return line from the AirDog to the injector
pump return T. Properly tighten the fittings. Secure the fuel line as necessary to
prevent abrasion and chaffing.

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 PureFlow Technologies, Inc.
AirDog FPII-150 CATERPILLAR 3406 A, B, & C
Section 6 Fuel Lines
Connecting the AirDog fuel supply line to the Fuel Tank!
6D-1. Inspect the fuel supply lines that connect the fuel tank(s) to the primary fuel filter
for size, length, and condition. If a fuel line has deteriorated or if it is too short to
connect to the AirDog, replace it or make an extension as necessary.
6D-2. If it is necessary to replace the fuel line, measure and cut the length of fuel line
required when properly routed and secured to make the connection from the fuel
tank to the AirDog. Assemble the fuel line per standard procedures.
6D-3. Route the fuel supply line from the fuel tank to the fitting on the AirDog fuel inlet
port marked IN.

Figure 24

Figure 25

6D-4. Connect the fuel supply line from the fuel tank to the fitting. Secure the line to
prevent chaffing and abrasion.

SECTION 7: The Caterpillar Secondary Fuel Filter Modification!

All Caterpillar diesel engines are equipped with a secondary fuel filter
mounted on the engine. The filter head usually has a Hand Primer Pump
attached to make priming and starting the engine easier after filter changes.
However, certain passage ways in the filter head and the valves in the hand
primer pump are restrictive to fuel flow and negatively affect engine
performance. Small, Restrictive Restrictive
Secondary Fuel Filter Passageway One-way Check
Valves

Hand Primer
1985 3406 B Pump
Figure 26 Figure 27 Figure 28
NOTE: In most cases, the filter head can be drilled out without removing it
from the engine!

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 PureFlow Technologies, Inc.
AirDog FPII-150 CATERPILLAR 3406 A, B, & C
Section 7 Secondary Fuel Filter

The Caterpillar Secondary Fuel Filter Modification!

Perform the following steps to improve fuel flow and engine performance.

7-1. Remove the hand primer pump and fuel filter from the filter head.

Restricted Passageway Un-restricted Passageway After

Before Porting Process Porting Process

Figure 29 Figure 30
7-2. Using a 3/8 bit, carefully drill out the
passage that carries the fuel into the fuel filter.

Figure 31
7-3. Remove all burrs and shavings then, install the
cap and gasket (included in the kit) on the filter head.
Also, re-install the fuel filter.

Figure 32

NOTE: The primer pump replacement cap (included in the kit)

has also been ported.

Figure 33

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 PureFlow Technologies, Inc.
AirDog FPII-150 CATERPILLAR 3406 A, B, & C
Section 8 Electrical Harness
ELECTRICAL HARNESS
VERY IMPORTANT: The AirDog electrical harness requires a MAXIMUM 15 Amp
Fuse!

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
Figure 34
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 35

Figure 36
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 37 Figure 38
8-3. Connect the lead with the green seal to the sensor switch.

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 PureFlow Technologies, Inc.
AirDog FPII-150 CATERPILLAR 3406 A, B, & C
Section 8 Electrical Harness

Routing the Indicator Light and Relay Trigger Lead

The Relay Trigger Lead must be connected to a contact point that is electrically 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.
To allow entry for the Indicator Light and Relay Trigger Lead through the firewall:
8-4. Peterbilts and Kenworths have access holes located below the steering column. Remove
the plug and route the leads through the hole.

Figure 39 Figure 40
8-5. For other make trucks, drill a 5/8" hole in firewall to allow entry of the Relay Trigger
Lead / Indicator Light harness into the cab.

Figure 41 Figure 42
8-6. Route the red, relay trigger wire and 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.

Be sure to seal the opening or install a grommet around the wire loom to prevent water
leakage and for protection from chaffing.

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 PureFlow Technologies, Inc.
AirDog FPII-150 CATERPILLAR 3406 A, B, & C
Section 8 Electrical Harness

Routing the Indicator Light and Relay Trigger Lead, contd!

8-7. Connect the Relay Trigger lead to a terminal on the ignition switch that is HOT when
the ignition switch is in the ON or RUN position.

Battery

OR

Ignition Accessory
Figure 43 Figure 44
8-8. Route the relay trigger lead (Red Wire) to the fuse panel and connect it to a fuse holder
that is HOT when the key is in the ON or RUN position.

INSTALLING THE LOW FUEL PRESSURE INDICATOR LIGHT.

Low Fuel Pressure Warning Light Kit!

Figure 45

8-9. Select a location on the dash board that is easily visible to the driver.

Figure 46

Figure 47

8-10. Remove the dash components as necessary to access the area behind the selected
location.

17
 PureFlow Technologies, Inc.
AirDog FPII-150 CATERPILLAR 3406 A, B, & C
Section 8 Electrical Harness

INSTALLING THE LOW FUEL PRESSURE

INDICATOR LIGHT, CONTD
8-11. Drill a 9/16 hole at the selected location. Be very careful when drilling. Do not
damage components located behind the dash.

Figure 48 Figure 49

8-12. Install the Dash Plate and Indicator Light in the dash. Connect the Indicator
Light Lead to the connector on the wiring harness.

8-13. Re-install the removed dash components to their original position.

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.
8-14. Route the Red & Black power supply leads to the alternator. Connect the Black (-)
ground lead to the alternator Ground connection.

Figure 50

Figure 51

8-15. Connect the Red (+) positive lead to the alternator Hot Lead going to the battery.

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 PureFlow Technologies, Inc.
AirDog FPII-150 CATERPILLAR 3406 A, B, & C
Section 9 Initial Startup

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 is purged of
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.

9-4. Start your engine!

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.

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 PureFlow Technologies, Inc.
AirDog FPII-150 CATERPILLAR 3406 A, B, & C
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
Pre-filter Nipple with
Wire Screen
Figure 51 (1 1/8th Inch Hex)

Prefilter/Water Separator
With Drain Valve
The Water Separator/Pre-filter
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.
VERY IMPORTANT: The AirDog electrical harness requires a MAXIMUM 15Amp Fuse!
Dispose of waste fuel and used filters properly to protect OUR environment!
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 PureFlow Technologies, Inc.
AirDog FPII-150 CATERPILLAR 3406 A, B, & C
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 Loose assemble the cap

careful not to dislodge or pinch screws. Torque the cap
the O-rings. screws in an opposing
pattern.

NOTE: Should any installation problems arise, for assistance please call toll free 1-877-463 4373
or 1-573-635-0555, Monday Friday, 8:00 AM 4:30 PM CST.

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 PureFlow Technologies, Inc.
AirDog FPII-150 CATERPILLAR 3406 A, B, & C
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 Orings.
Regulator Components

A - Adjustor Screw
B - Jam Nut A
C - Base Nut Figure 52
D - Spring B
E - Plunger C
F - Plunger Oring D
F E

STEP 1 STEP 2 STEP 3

Loosen Jam Nut B and Turn Adjustor Screw A Remove the Adjustor Assembly from
regulator base nut C. Counter clockwise to remove the AirDog base. Be careful to not
the assembly. damage the Orings or lose the
regulator spring or plunger.
STEP 4 STEP 5 STEP 6

Be sure the Regulator Plunger and Tighten the Base Nut. Re-adjust the output pressure by
Spring are properly positioned, turning the Adjustor Screw counter
then
: carefully insert the Adjustor clockwise until it stops against the
Assembly into the base. Turn the Base Nut. Then, turn the Adjustor
assembly clockwise until the base Screw in, clockwise 2.5 turns.
nut is flush with the surface of the NOTE: Units built after December
AirDog base. 1, 2013 require 2.5 turns. Units
built before December 1, 2013
require 5 turns.
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NOTES

23
Copyright 2014 Bulletin No. 206-1-0401
CD Patents, LLC Revised January, 2014
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