Cat Manual-3406 E, c13, c15, c16 Acert Jan 2014

Providing Test Cell Performance in Real World Conditions Since 1993!
industrial
The Original Fuel Air Separation System
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, J apan, and China!

Kit No. A3SPBT451

PLEASE READ
THESE INSTRUCTIONS
THOROUGHLY
BEFORE BEGINNING
INSTALLATION
INSTALLATION MANUAL
For Trucks Equipped with CATERPILLAR

Model 3406 E, C13, C15, OR C16 Engines
NOW WITH DEMAND FLOW
2
THE RIGHT CHOICE FOR YOUR DIESEL ENGINE!
New Design 4G-HD Fuel Pump (4
th
generation)
Pump Shaft, stabilized with bearings on each end, holds the Gerotor
in virtually perfect alignment for quiet running and extended
longevity!
New Quick Change Motor
If necessary, the motor can be
removed and replaced in a matter
of minutes.
Water Separator/Prefilter
Long Lasting Wire Mesh Media
6 Micron Particulate Filters
Long Lasting MicroGlass Media
Positive Air Separation
With Primary Air Discharge
Port
CARB Executive Orders No. D-595-1 & D-595U-1, permit the advertisement, sales, and
installation in California of AirDog
, AirDog
II, Fuel Preporator
, and Fuel Preporator
II

Bearing
Protective Wire Screen
In Water Separator Nipple!
FPII-150 & FPII-200 8 W X 3 7/8 D X 12 T FPII-125 7 W X 3 D X 10 T

Dual Port Pump
Balances the Gerotor
for Quiet Operation
and Higher Flows!
Adjustable Regulator
For Just the Right Fuel
Demand Flow System!
Easy Installation, Only One
Small Line Connected to the
Engine Return Line to Return
Air / Vapor to the Tank!
New Micro Processor
Fuel Filter Monitor
Lets you know when to
Service the Fuel Filter &
Water Separator before
suffering power loss
NO MORE GUESSING!

industrial
3
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 3406E, C13,
C15, or C16 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-200 CATERPILLAR 3406E, C13, C15, & C16
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.....................Mounting AirDogOn Truck
Fuel Lines, Fittings & Pressure Sensor Switch
Section 6A.............................................................Fittings & Sensor Switch
Section 6B.........................................Removing ACERT Recycle Fuel Line
Section 6C...................................Fuel Line from AirDogto Engine
Section 6D.......................................AirDogFuel Return to Tank
Section 6E.....................From Tank to AirDog
Fuel System Upgrade
Section 7A.........Fuel Line from Transfer Pump to
. Secondary Filter Head
Section 7B..................................................Fuel Line from Secondary Filter
. Head to Engine Head
Section 7C...............................Secondary Fuel Filter Head
Modification
Electrical Harness
VERY IMPORTANT: The AirDogelectrical harness requires a MAXIMUM 15Amp Fuse!
Section 8...........................Electrical Harness
Final Checks
Section 9.....................................Initial Start Up
Adjusting Fuel Pressure
Section 10...............Resetting Fuel Rail Pressure
Maintenance
Section 11...........................Filter Service Recommendations
Section 12.................................Cleaning the Gerotor Assembly
Section 13.......................................................AirDogPressure Regulator
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Technologies, Inc.
Section 2 Installation & Safety Guidelines

Caterpillar 3406E, C15, & C16 engines require an upgrade to the secondary fuel lines and
filter head. The components needed for this are listed in blue in the parts list.

C-15 ACERT Engines require an additional upgrade, see page 20.

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.
(Loctite545 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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Technologies, Inc.
Section 3 Parts List

Installation Parts List with Return Line Kit & Fuel System Upgrade Components
QTY DESCRIPTION Part Number IMAGE
1 Installation Manual 206-1-0402

1

AirDog
FPII-200

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

1 Hardware Kit, Includes:
4ea 3/8 x 1-1/2 Hex Head Bolt,
4ea 3/8 Nut
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

901-08-0100

1
Wiring Harness with Microprocessor &
Indicator Light and Dash Plate Plus Grommet
5E-2-3370-12
201-3-0004
5J -1-1-04-2758
1 Fuel Pressure Sensor 5C-9-007
2 #10 - JIC Flare x 1/2 NPT Fitting 4A-1-01-10-08-B

2 #10 - 90
0
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

1
9/16-18 x #8 JIC AirDog Return line Restrictor Fitting
4A-1-01-08-06-S-.16M

1
#8 - Female Swivel x #8 Male Flare x Return T
4A-1-11-08-08-4P

1 #8 Swivel X #6 X #6 - Air/Vapor Return T 4A-4-04-06-08-06-4-S

1 #6 - JIC Flare x NPT Return Fitting 4A-1-01-A-C-SZ

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 #10 - ORB X JIC Flare (ACERT Pump Fitting) 4A-1-02-10-08-S

1 #10 - 90
0

2 #8 - 90 Swivel x Fuel Line End 4A-2-13-08-08-S

2 #8 - Swivel x Straight Fuel Line End 4A-1-13-08-08-S

2 #8 - 90
0

4 9/16-18 ORB x #8 Flare Fuel Fittings 4A-1-01-08-06-S
1 8ft Section #8 Steel Braid Reinforced Fuel Line 4C-1-08-08

1
Hand Primer Pump Includes.....1 - Cap
Replacement Kit: 1 - Gasket
002-4G-0006
002-4G-0007
1 Caterpillar Fuel Pressure Shim Kit 905-01-0100-1

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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 AirDogat 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 AirDogcan 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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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: DO NOT mount the AirDog
on the engine! Mounting the AirDog
on the
engine will immediately void your AirDog
warranty.

5-3. Loose assemble the mounting brackets and filters to the AirDog
.

Figure 7 Figure 8
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.
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Section 5 Mounting the AirDog

MOUNTING THE AirDog
, contd!

5-5. While holding the AirDog
at the selected mounting location on the frame, mark

and center punch each hole location.

Figure 9 Figure 10
5-6. Drill a 3/8 hole at each of the 4 previously marked locations.

WARNING! DO NOT DRILL INTO OR DAMAGE ANY WIRING, AIR LINES OR
OTHER COMPONENTS LOCATED BEHIND THE FRAME RAIL.

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

Figure 11

Figure 12

5-8. Loose assemble the AirDog
on the brackets.

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.

Figure 13

NOTE: These steps are necessary to prevent stress cracks from forming in the
mounting brackets due to road vibration and bouncing.
10
Transfer Pump
Secondary
Fuel Filter
Caterpillar C15 Engine
Fuel Line at
Back of Head
PureFlow
Technologies, Inc.
Section 6 Fuel Fittings & Fuel Pressure Sensor

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 fuel 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 AirDogin 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 AirDogand 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.

Figure 14
11
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.
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Technologies, Inc.
Section 6 Fuel Fittings & Fuel Pressure Sensor

Section 6A: Installing the Fuel Fittings and Low Fuel Pressure
Sensor Switch!

IMPORTANT: Use diesel compatible thread sealer when installing NPT fittings.

NOTE: Figures 15 & 16 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 J IC x NPT fuel fitting in the AirDogfuel port marked
ENGINE. Use a 90 swivel fitting as needed when connecting the fuel line.

Figure 15

Figure 16
6A-2. Install a straight #10 J IC 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 J IC Male return fitting into the Air/Vapor return port
marked TANK.

Figure 17

Figure 18

6A-4. Remove the 1/8 NPT plug from the end of the pre-installed 45
0
fitting in the
AirDog
base. Install the pressure sensor switch into the 45

0
fitting.

12
OR
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Section 6 Fuel Lines

Section 6B: Caterpillar ACERT Fuel System!
Caterpillar ACERT Engines have a Return Fuel Recycle Line. This fuel line recycles
HOT fuel, coming directly from the engine head, back to the fuel inlet port of the
transfer pump.

For BEST FUEL ECONOMY and MAXIMUM ENGINE EFFICIENCY,
the Return Fuel Recycle Line must be removed!

Figure 19
6B-1. Disconnect the Return Fuel Recycle Line from the top of the inlet fitting at the transfer pump.
6B-2. Disconnect the Return Fuel Recycle Line from the bottom of the Return Line shutoff valve
6B-3. There is a bracket on the Return Fuel Recycle Line that secures the line to the block.
Remove the bolt holding the bracket. Remove the Return Fuel Recycle Line from the engine.
6B-4. Disconnect the fuel supply line from the bottom of the inlet fitting at the transfer pump.
6B-5. Remove the Transfer Pump inlet fitting.

Figure 20 Figure 21

6B-6. Install the ORB X #10 J IC flare fitting 6B-7. Reconnect and tighten the fuel supply
in the Transfer Pump Inlet Port. line removed in step 7A-4.

Note: Use the 90
0
#10 Swivel X #10 J IC Flare fitting, as needed!
View of Transfer Pump
From Front Of Engine
View Of Secondary Filter Head
From Drivers Side Of Engine
Fuel Return Line
From Head
Fuel Transfer
Pump
Fuel Supply Line
From Primary Filter
and Fuel Tank
High Pressure
Fuel Line
Secondary Fuel Filter Head
(Hand Primer Pump Removed)
Return Fuel Recycle
Shutoff Valve
Fuel Rail Pressure
Regulator
Return Fuel
Recycle Line
Transfer Pump
Inlet Fitting
13
Small ID ORB Port Larger ID J IC Port
PureFlow
Technologies, Inc.

Section 6C: Fuel Line from the AirDog to the Engine!

NOTE: The ORB end of the fuel fitting has a much smaller bore than the JIC flare
end. The small hole in the ORB portion of the fitting, opening into the greater
volume area at the inlet to the transfer pump, creates a Vacuum Chamber and a
pressure drop that can cause vapor to form.

Figure 22
To facilitate fuel flow and eliminate the Vacuum Chamber affect, the ORB end of
the fitting must be enlarged.

6C-1. Disconnect the fuel line from the fitting and remove the fuel fitting from the
transfer pump.

Figure 23

Figure 24

6C-2. Drill out the passage way in the ORB end of the fuel fitting to 15/32. Clean out all
burrs and re-install the fitting back into the transfer pump.

6C-3. Connect the fuel line originally connecting the primary fuel filter to the transfer
pump, to the AirDogout to Engine port. If the fuel line is in poor condition or
too short to make the connection, replace it with a new fuel line!

Figure 25 Figure 26
6C-4. Re-connect the fuel line to the transfer pump.

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SECTION 6D: Installing the AirDog
Return Line

The AirDog returns entrained air & vapor to the fuel tank. The AirDog Air/Vapor
return line may be connected directly to the engine fuel return line Low Pressure side
after the regulator.

Connecting the AirDog
Air/Vapor return to the engine fuel return line!

6D-1. Disconnect the fuel return line connected to the fuel return fitting on the
secondary filter and remove the #6 fitting. Install the Special AirDog9/16-18
ORB X #8 Restrictor Fitting in the Return to Tank port in the secondary filter
head.

Figure 27 Figure 28
6D-2. Assemble the correct AirDogreturn T to the Restrictor fitting. Install the #8
Swivel X #6 X #6 :T, if you have a #6 engine return line . Install the #8 T and
fitting if you have a #8 engine return line, as shown in Figure 31.

Note: Figure 28 shows the engine return with #6 T.

6D-3. Measure and cut the length of fuel line required, when properly routed, to
connect the AirDogAir/Vapor return port to the new return T installed on the
secondary fuel filter head. Assemble the fuel line per standard procedures.

6D-4. Connect the new return line to the AirDogAir/Vapor return port, ref. Figure 29.

#6 T with Return Line #8 T Components

Figure 29 Figure 30 Figure 31
6D-5. Route and connect the other end of the Air/Vapor return line to the newly installed
return T.

Important: Properly tighten the fittings. Secure the fuel line as necessary to prevent
abrasion and chaffing.
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Connecting the AirDog fuel supply line to the Fuel Tank!

6E-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.

6E-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 Fuel AirDog
. Assemble the fuel line per standard procedures.

6E-3. Route the fuel supply line from the fuel tank to the fitting on the AirDog
, fuel inlet
port marked IN.

Figure 32

Figure 33

6E-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 System Upgrade!

7A: Upgrading the fuel line from the transfer pump to the secondary fuel
filter.

NOTE: The passageways in the original 9/16 -18 x #6 fuel fittings
and #6 lines are small and restrictive to the fuel flow.
Upgrading the system with ported #8 fittings and installing
#8 fuel lines increases fuel flow and performance.
Figure 34
7A-1. Disconnect the fuel line from the discharge side (high pressure side) of the
transfer pump.

Figure 35 Figure 36
7A-2. Remove the #6 fuel fitting in the transfer pump and install the 9/16-18 ORB x #8
ported fitting.
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Section 7 Fuel System Upgrade

Section 7A: Upgrading the fuel line from the transfer pump to the secondary
fuel filter, contd!

7A-3. Remove the other end of the fuel line from the inlet fitting on the secondary fuel
filter.

Figure 37 Figure 38

7A-4. Remove the #6 fuel fitting in the secondary filter head and install the 9/16-18
ORB x #8 ported fitting.

7A-5. Measure and cut the length of fuel line required, when properly routed, to
connect the new #8 ported fitting in the transfer pump to the new fitting
installed in the secondary fuel filter head inlet fitting. Attach the proper ends.
Assemble the fuel line per standard procedures.

Figure 39

7A-6. Connect the end with the 90
0
fitting to the transfer pump. Be careful to
position the fuel line with proper clearance.

Figure 40 Figure 41

NOTE: DO NOT position the fitting and fuel line too close to the harmonic balancer as
shown in Figure 41. Be sure to have adequate clearance!
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Section 7A: Secondary Fuel Lines, contd!
Replacing the fuel line from the transfer pump to the secondary fuel filter, contd.

7A-7. Route the fuel line to the secondary fuel
filter and connect the other end to the
newly installed #8 fitting. Use the 90
0
fitting
as necessary. Properly tighten the fuel lines.
to the fittings
Figure 42

Section 7B: Replacing the fuel line from the secondary fuel filter to the engine head!

7B-1. Disconnect the fuel line from the secondary fuel filter and remove the #6 fitting
from the port marked To Head.

Figure 43 Figure 44
7B-2. Install a new Ported ORB x #8 fuel fitting in the filter head in place of the fitting
just removed.

7B-3. Follow the #6 fuel return line from the secondary filter head to the back of the
engine head. Disconnect the fuel line from the fitting in the back of the head and
remove the #6 fitting.

Figure 45 Figure 46
7B-4. Replace the original #6 fitting with a Ported #8 x ORB fitting.

NOTE: The return line just disconnected will be re-connected at a different
location.
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Section 7B: Replacing the fuel line from the secondary fuel filter to the engine
head, contd!

7B-5. Measure and cut the length of #8 fuel line required, when properly routed, to
connect the new #8 Ported ORB fitting in the secondary fuel filter head to the
new #8 fitting installed in the back of the engine head. Attach the proper ends
and assemble per standard procedures.

Figure 47
7B-6. Connect the 90
0
end of the new #8 fuel line to the fitting in the TO HEAD port in
the secondary fuel filter head.

Figure 48 Figure 49
7B-7. Connect the other end of the new #8 fuel line to the Ported #8 fitting in the back
of the head. Properly tighten all fuel line connections.

7B-8. To reconnect the #6 fuel return line that was disconnected from the back of the
engine head, reroute it to the original fuel inlet block, and connect the fuel return
line to the fitting shown in Figure 51.

Figure 50 Figure 51

Use a 90
0
fitting as
necessary!
19
Restrictive One-way Check
Valves in Hand Primer Pump
Small, Restrictive
Passageway
Compare the
check valves and
port sizes to a
dime!
Note: Remove the primer
pump bypass valve before
porting this passageway!
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7C: Secondary Fuel Filter Head 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, the passageway in the filter head, ref. Fig. 52, and the valves in the hand primer
pump are restrictive to the fuel flow through the system and to the engine head and
negatively affect engine performance. This passageway must be enlarged to allow better
fuel flow through the filter head.

Figure 52 Figure 53

NOTE: Perform the following steps to improve fuel flow and engine
performance. In most cases, the filter head can be drilled out without
removing it from the engine!

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

7C-2. Using a 3/8 bit, carefully drill out the passageway that carries the fuel from the
primer pump into the fuel filter.

Figure 54 Figure 55
NOTE: Be careful not to drill into the fuel filter gasket seat on the underside
of the filter head.
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7C: Secondary Fuel Filter Head Modification

7C-3. Remove all burrs and shavings from the filter head.

Figure 56

7C-4. Install the hand primer pump replacement cap and gasket on the filter head.
Also, re-install the fuel filter.

NOTE: The primer pump replacement cap (included in the kit)
cross passage has also been ported to 3/8 for better
fuel flow.
Figure 57

This picture shows a #8 Low Pressure Side fuel return line.

Completed upgrade to the secondary fuel filter!
Figure 58
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Section 8 Electrical Harness

ELECTRICAL HARNESS

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.

AirDogPump Motor Lead

Pressure Sensor/Switch Lead

Indicator Light & Lead

Battery Positive Lead

Battery Negative Lead

Relay Lead
Figure 59
Securing the Microprocessor to the Vehicle
8-1. Secure the Microprocessor to the vehicle. Secure the Microprocessor to the
vehicle. This picture shows the Microprocessor mounted next to the steering
column.

Figure 60

Figure 61
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 62 Figure 63
8-3. Connect the lead with the green seal to the sensor switch.
22
By the Steering Column Under the Dash
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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.

Routing the Indicator Light and Relay Trigger Lead through the firewall:

8-4. Most Peterbilts and Kenworths have access holes located below the steering
column. Remove the plug and route the leads through the hole.

Figure 64 Figure 65
8-5. For other applications, drill a 5/8" hole in firewall to allow entry of the Relay
Trigger Lead / Indicator Light lead into the cab. Be sure to seal around the loom.
Use a grommet when necessary.

Figure 66 Figure 67

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 for protection from chaffing.
23
Ignition
Accessory
DO NOT
Connect Here
Battery
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Routing the Indicator Light and Relay Trigger Lead, contd!

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

Figure 68 Figure 69
8-8. Route the relay trigger lead (Red Wire) to the fuse panel and connect to a fuse
holder that is HOT when the key is in the ON or RUN position.

INSTALLING THE FUEL FILTER
INDICATOR LIGHT.

Figure 70

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

Figure 71

Figure 72

8-10. Open or remove the dash components as necessary to access the area behind
the selected location.
24
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INSTALLING THE FUEL FILTER CHANGE
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 73

Figure 74

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 leads to the alternator. Connect the Black
(-) ground lead to the alternator Ground connection.

Figure 75

Figure 76

8-15. Connect the Red (+) positive lead to the alternator Hot Lead going to the battery.
25
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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, it is suggested to pre-fill the water
separator/pre-filter with diesel fuel 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!

9-5. Go to Section 10 for instructions to check and adjust the fuel rail pressure

RECHECK ALL FUEL FITTINGS FOR LEAKS. BE SURE ALL LINES ARE
PROPERLY SECURED TO PROTECT FROM CHAFFING AND ABRASION.
RECHECK ALL ELECTRICAL LINES, SECURE AS NECESSARY.

SECTION 10: Adjusting the Fuel Rail Pressure

Temporarily, install a 150 PSI fuel pressure gauge.
It is important to know the original fuel pressure before you start!

Figure 77 Figure 78

Connect the
Pressure Gauge
Here!
26
Enlarged view of
spring and pin/cap
A
C
D
Shim Kit
B
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Section 10 Fuel Rail Pressure

Adjusting the Fuel Rail Pressure

For the Cat 3406E, C15, and C16 engine to perform at peak efficiency, the fuel rail
pressure must be adequate to completely fill the fuel injectors during the up stroke of the
plunger. A minimum of 115 PSI to an absolute maximum of no more than 120 PSI at high
idle is required.

NOTE: The first step to resetting the Fuel Rail Pressure has already been performed
when the AirDog 9/16-18 ORB X #8 Special Return Fitting was installed in Step 6D-1. If
your transfer pump is in good condition and not worn out, with the engine running the fuel
rail pressure should be at approximately 118PSI at high idle (1,900 to 2,100 RPM). If the
fuel rail pressure is still low, follow the steps below.

There are two models of the Caterpillar fuel transfer pump. The earlier model transfer
pump, with a small diameter spring and hex head plug, as shown in Figure 79, and the
later version, with a larger diameter spring and socket head plug, as shown in Figure 80.

To adjust the rail pressure it is necessary to reset the spring tension on the high pressure
bypass regulator.

Figure 79 Figure 80 Figure 81
EARLY STYLE PUMP LATER STYLE PUMP
To Adjust the Earlier Style Cat Fuel Transfer Pump (Figure 79)

10-1. Remove hex plug A on the side
of the transfer pump.
10-2. Take out spring C and Stiffener Pin B.
NOTE: The shim kit includes new stiffener pin
with cap and three shims for the early
version transfer pump.

Figure 82

10-3. Put the new stiffener pin w/cap part #D into the spring and re-install in transfer
pump.
10-4. Start the engine. Run the RPM up slowly until high idle is reached. High idle is
1,900 to 2,100 RPM. Read the fuel rail pressure. If the rail pressure does not
reach 115 PSI, add a shim and repeat until at least 115 PSI, but not more than
120 PSI, is reached.
27
C
B
A
B
A
OE Spring &
Plug
OE Spring &
Plug with shim
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Section 10 Fuel Rail Pressure

Adjusting the Fuel Rail Pressure, contd

Adjusting Rail Pressure for the Later Style Cat Fuel Transfer Pump.
reach 115 PSI, add a shim and repeat until at least 115 PSI, but not more than
120 PSI, is reached.

WARNING: Do Not exceed 120 PSI fuel rail pressure. High rail pressure, 130 PSI and
above will void you factory engine warranty and may cause engine damage!

10-6. Remove socket head plug A on the side of the transfer pump.

NOTE: The Shim Kit includes two shims, one 0.25 thick and one 0.125 thick.

Figure 83 Figure 84
10-7. Hold the 0.125 shim C on the end of the plug A and re-install the spring,
shim, and plug into the transfer pump.

reach 115 PSI, replace the 0.125 shim with the 0.25 and repeat adjusting shims
until 115 PSI, but not more than 120 PSI is reached at high idle.

WARNING: Do Not exceed 120 PSI fuel rail pressure. Excessively high rail pressure, 130
PSI and above will void you factory engine warranty and can cause severe
engine damage!

10-9. When you have completed adjusting the fuel rail pressure, remove
the pressure gauge from the secondary fuel filter head and replace
the plug.

Very Important: If you are unable to adjust the fuel rail pressure to the 115
PSI level, it is possible that your transfer pump is worn out and should be
replaced. To obtain PEAK PERFORMANCE and fuel economy from your
Caterpillar engine, all components must be in good to excellent operating
condition.
28
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Section 11 Servicing 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 AirDogIndicator 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.

Figure 85

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.

Dispose of waste fuel and used filters properly to protect OUR environment!
AirDog
Fuel Filter
Prefilter/Water Separator
With Drain Valve
Pre-filter Nipple with
Wire Screen
1 1/8 In Hex
29
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Section 12 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 the
gerotor cap. damage 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 screws.
careful not to dislodge or pinch Torque the cap screws in an
the O-rings. 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.
30
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Section 13 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.

A - Adjustor Screw
B - J am Nut
C - Base Nut Figure 86
D - Spring
E - Plunger
F - Plunger Oring

:

A
B
C
D
E
Regulator Components
STEP 1 STEP 2 STEP 3
Loosen Jam Nut B and
regulator base nut C.
Turn Adjustor Screw A
Counter clockwise to remove
the assembly.
Remove the Adjustor Assembly from
the AirDog base. Be careful to not
damage the Orings or lose the
regulator spring or plunger.
STEP 4 STEP 5 STEP 6
Be sure the Regulator Plunger and
Spring are properly positioned,
then carefully insert the Adjustor
Assembly into the base. Turn the
base nut clockwise until it is flush
with the surface of the AirDog
base.
Tighten the Base Nut. Re-adjust the output pressure by
turning the Adjustor Screw counter
clockwise until it stops against the
Base Nut.
NOTE: Units built before
December 1, 2013 require 5 turns.
F
31

NOTES

32

Copyright 2014 Bulletin No. 206-1-0402
CD Patents, LLC Revised January, 2014
All Rights Reserved

Cat Manual-3406 E, c13, c15, c16 Acert Jan 2014

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Providing Test Cell Performance in Real World Conditions Since 1993!

II, Fuel Preporator

, and Fuel Preporator

Technologies, Inc. for technical assistance.

as close to the original location of the primary fuel filter as

on the engine! Mounting the AirDog

at the selected mounting location on the frame, mark

on the brackets, snug the fasteners to achieve a

has been engineered to eliminate fuel related problems. It is important that

Air/Vapor return line can be connected to the

or between the AirDog

and the engines transfer pump to plug

base. Install the pressure sensor switch into the 45

Air/Vapor return to the engine fuel return line!

, replace it or make an extension as necessary.

. Assemble the fuel line per standard procedures.

wiring harness has a Microprocessor and two color LED indicator

, Microprocessor wiring harness.

is a self priming system. However, to prevent damage to a dry seal and

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