Dahl 200 and 300
Dahl 200 and 300
SERIES
Diesel
Fuel/Water
Separators
• Installation
• Operation
• Parts
• Service Information
200 & 300 SERIES
INSTALLATION
A. FILTER MOUNTED ABOVE FUEL STORAGE TANK ___________________________
1. Select a location in the fuel line between the fuel tank and the NOTE: Allow 2 1/2 inches vertical clearance below the unit for
fuel pump, ahead of the vacuum side filters. All secondary or servicing the element and draining the contaminants.
pressure side filters located between the pump and the engine 3. Install the fuel line from the fuel tank to the DAHL filter INLET
should be serviced and left in place. using appropriate non-ga l vanized fittings. See DAHL Fittings
2. Mount the DAHL unit vertically on the vacuum (suction) side Chart on Page 3.
of all fuel pumps in a convenient location for servicing and 4. Install the fuel line from the DAHL filter OUTLET to the
inspection of contaminants in the bowl. Locate the height of INLET of the transfer or fuel pump.
the unit between the bottom of the fuel tank and the inlet of the NOTE: To obtain maximum element life, remove as much
fuel pump if possible. See Figure 1. mechanical restriction as possible from the system by
doing the following:
FIGURE 1 a. Remove the primary filter (if this does not affect warranty).
b. Use the largest diameter fuel line that is practical.
c. Mount the unit as near to the level of the pump as possible.
d. Eliminate sharp bends in the fuel lines wherever possible.
REBUILD PROCEDURE
If it is ever necessary to dismantle the unit for inspection and/or 4. Check all parts for damage. Replace all damaged parts or hard
possible repairs, refer to the parts illustration. Then follow these gaskets. (Order Gasket Kit 200-GK.)
simple steps: 5. Refer to the parts illustration for reassembly. Clean all gasket
1. Refer to appropriate ELEMENT REPLACEMENT steps for grooves and contact surfaces of foreign matter. Coat the lid
disassembly. (Dismount if desired.) cover and bowl gaskets with grease and all other gaskets and
2. Remove the socket head bolts from the bowl ring to release the O-Rings with oil. Hand tighten the depressurizer cone and
bowl. Stubborn bolts are easily removed by “shocking” the head. wrench tighten the socket head bolts.
Place the allen wrench into the bolt and lightly rap the wrench 6. Again, refer to ELEMENT REPLACEMENT section to finish
with a hammer. Remove the bolt. reassembly.
3. Unscrew the depressurizer cone to inspect the reverse flow valve.
Caution: Cone edges are sharp. Use gloves or a rag for protection.
2
200 & 300 SERIES
DAHL FITTINGS CHART
Note: Mount Model Before Installing Fittings. O-Ring Seal Fittings Require Care in Installation. DO NOT OVERTIGHTEN. See
Instructions Below.
FITTING FOR DAHL UNIT THREAD 1 THREAD 2 ORDER NUMBER
90° Elbow 200 Series 7/8-14 UNF 3/4-16 1010-10x8 OBS
1 200 Series 7/8-14 UNF 7/8-14 1010-10x10
Straight T h r e a d 300 Series 1 1/16-12 UNF 7/8-14 1010-12x10 OBS
with O-Ring/37° 300 Series 1 1/16-12 UNF 1 1/16-12 1010-12x12
Male JIC 2
37° Female JIC 200 Series 3/4-16 1/2 Hose 1030-8x8 OBS
1 2 200 & 300 Series 7/8-14 5/8 Hose 1030-10x10 OBS
Swivel-Push-On 300 Series 1 1/16-12 3/4 Hose 1030-12x12
Hose Fitting
Female Pipe 200 Series 7/8-14 UNF 3/8-18 NPT 1040-10x6
200 Series 7/8-14 UNF 1/2-14 NPT 1040-10x8 OBS
Straight T h r e a d 1 2 200 Series 7/8-14 UNF 3/4-14 NPT 1040-10x12
with O-Ring 300 Series 1 1/16-12 UNF 1/2-14 NPT 1040-12x8
300 Series 1 1/16-12 UNF 3/4-14 NPT 1040-12x12
90° Swivel Elbow 300 Series 1 1/16-12 UNF 3/4-14 1015-F
Straight Thread with O-Ring/37° Female JIC
90° Swivel Elbow
Straight Thread with O-Ring/37° Female JIC 200 Series 7/8-14 UNF 1/2-14 1015-DDT
Drilled & Tapped for #4 Vacuum Gauge Hose
1 Install “Out” Port First 2 Screw in O-Ring fitting until washer contacts port 3 4 Hold fitting by hand in desired position
Hand Tighten Do NOT and tighten compression nut with wrench.
Only Use Wrench
3
200 & 300 SERIES
SERVICING
DRAINING WATER ___________________________________________________
NOTE: The bowl should always be drained before water or 3. Close the draincock and follow the priming instructions
contaminant levels reach the bottom of the depressurizer shown below.
cone. Check daily with the engine off. Always open the B. DAHL Units Mounted LOWER Than Fuel Storage Tank
draincock completely to flush particulates out. Failure to 1. Turn engine off and close shut-off valve. (Valved Manifold
do so could cause a leaky valve. units may be drained and elements replaced with the engine
running at idle. Close inlet and outlet valves to islolate the
A. DAHL Units Mounted HIGHER Than Fuel Storage Tank filter being serviced.)
1. Turn engine off. Vent the DAHL filter to allow draining. 2. Open the draincock completely and drain all contaminants.
2. Open the primer plug and then open the draincock and drain 3. Close the draincock and follow the priming instructions
all contaminants. shown below.
TROUBLESHOOTING
Engine starting and power loss problems from the fuel system are B. Clogging And Restriction
usually caused by one or more of the following: 1. Fuel Lines. Check for collapsed lines caused by sharp bends or
A. Air Leaks excessive turns. Check the tank and/or filter shut-off valve(s).
1. Fittings. Insure the O-Rings on the fittings in the DAHL 2. Filter Elements. Early clogging can occur from badly
filter ports are lubricated and not damaged, cracked or dirty. contaminated fuel (micro-organism growth, rust, sludge, dirt,
NOTE: When using JIC 37° fittings, be sure only mating JIC 37° etc.) Always carry a spare DAHL element. Asphaltinic
fittings are used. Misalignment will occur and air leakage materials (fuel oxidation products), which are normally
will result from an attempt to fasten a SAE 45° fitting to harmless to the injection system, can eventually plug original
a JIC 37° fitting. Check for fitting looseness, seat dents, equipment filters remaining in the fuel system. If problems
misalignment or unmatched threads. All fittings must be persist after the DAHL element has been replaced, also
wrench tight. replace the other fuel filter elements.
2. Bubbles In The Bowl. If bubbles appear at the depressurizer 3. Filter Inlet. Severely contaminated fuel may cause inlet
cone, a leak is indicated between the fuel tank and the inlet plugging. In this event, close the fuel tank supply shut-off
port. valve (if equipped) and disconnect the inlet line. Remove the
NOTE: Old fuel lines (rubber hose or metal tubing) may crack bowl and clean the inlet. Should the depressurizer cone also
when moved. Check areas around push-on fittings, pipe be plugged, disassemble and clean out.
adapters, hose clamps, etc. If air bubbles appear at the 4. Bleed Back. If fuel in the DAHL filter bleeds back to the fuel
draincock, check for particles stuck in the valve seat or a tank, an air leak or reverse flow valve problem is indicated.
partly open draincock. Also check for defective, Inspect fuel lines and fittings first as indicated above. If the
miscentered or unlubricated bowl gaskets. Check the reverse flow valve is clogged, use air or clean fuel to flush
bowl plug O-Ring to make sure it is not cracked or out.
extruded out of place. The bowl plug should be hand C. Malfunction Of Engine Parts
tightened only. Pre-existing conditions in the pumps and injectors can also
3. Gaskets. If the lid or bowl has been removed, make sure the cause power loss and engine starting problems. See your
gasket grooves are clean. Inspect the ga s kets for proper seating equipment dealer if the above troubleshooting guides do not
in the grooves. Lubricate the ga s ket(s) with oil or grease. cover your problem.
WARNING: Do NOT use gasoline or any form of alcohol or anything containing it inside or outside a DAHL
Model 200 or 300 Series Fuel/Water Separator.
4
200 & 300 SERIES
MODEL 200 SPECIFICATIONS & PARTS ________________________________
Recommended Flow Rate: 120 GPH (U.S.) (454 LPH)
Port Thread: 7/8-14 w/O-Ring Boss
Height: 16 3/4 In. (425.5 mm)
Width: 7 1/2 In. (190.5 mm)
Depth: 7 3/4 In. (196.9 mm)
Weight: 12 lbs. (5.4 kg)
Item Order # Qty. Description
1 200-10P 1 T-Bolt
2 200-14 1 Lid Cover
3 1 Lid Cover Gasket (Incl. in 200-GK)
4 200-16 1 Body
5 1 Bowl Gasket (Incl. in 200-GK)
6 200-20 1 Bowl Ring
7 200-33 8 Socket Head Bolt
8 1 Reverse Flow Washer
(Incl. in 200-GK & 200-DEPR KIT)
9 1 Depressurizer Set
(Incl. in 200-DEPR KIT)
10 1 Bowl Collar
11 200-31 1 Primer Plug
12 1 Primer Plug O-Ring (Incl. in 200-GK)
13 1 Nylon Gasket (Incl. in 200-GK)
14 1 Upper T-Bolt Seal (Incl. in 200-GK)
15 1 Lower T-Bolt Seal (Incl. in 200-GK)
16 1 Centerpipe O-Ring (Incl. in 200-GK)
17 201,-W,-30 1 Filter Element
18 200-18 4 Ejector Spring
19 200-34 4 Ejector Spring Clip
20 1 Reverse Flow Gasket
(Incl. in 200-GK & 200-DEPR KIT)
21 1 Reverse Flow Ball
(Incl. in 200-DEPR KIT)
22 200-21 1 Bowl
23 1 Bowl Plug O-Ring (Incl. in 200-GK)
24 100-29 1 Bowl Plug
25 100-30 1 Draincock
5
200 & 300 SERIES
MODEL 300 SPECIFICATIONS & PARTS ________________________________
Recommended Flow Rate: 180 GPH (U.S.) (681 LPH)
Port Thread: 1 1/16-12 w/O-Ring Boss
Height: 22 1/4 In. (565.2 mm)
Width: 7 1/2 In. (190.5 mm)
Depth: 7 3/4 In. (196.9 mm)
Weight: 16 lbs. (7.3 kg)
Item Order # Qty. Description
1 200-10P 1 T-Bolt
2 300-14 1 Lid Cover
3 1 Lid Cover Gasket (Incl. in 200-GK)
4 300-16 1 Body
5 1 Bowl Gasket (Incl. in 200-GK)
6 200-20 1 Bowl Ring
7 200-33 8 Socket Head Bolt
8 1 Reverse Flow Washer
(Incl. in 200-GK & 200-DEPR KIT)
9 1 Depressurizer Set
(Incl. in 200-DEPR KIT)
10 1 Bowl Collar
11 200-31 1 Primer Plug
12 1 Primer Plug O-Ring (Incl. in 200-GK)
13 1 Nylon Gasket (Incl. in 200-GK)
14 1 Upper T-Bolt Seal (Incl. in 200-GK)
15 1 Lower T-Bolt Seal (Incl. in 200-GK)
16 1 Centerpipe O-Ring (Incl. in 200-GK)
17 301,-W,-30,
-MPG,-CS 1 Filter Element
18 200-18 4 Ejector Spring
19 200-34 4 Ejector Spring Clip
20 200-22 1 Reverse Flow Gasket
(Incl. in 200-GK & 200-DEPR KIT)
21 200-24 1 Reverse Flow Ball
(Incl. in 200-DEPR KIT)
22 200-21 1 Bowl
23 200-32 1 Bowl Plug O-Ring
24 100-29 1 Bowl Plug
25 100-300 1 Draincock
6
200 & 300 SERIES
MODEL 300-MFV SPECIFICATIONS & PARTS ___________________________
Recommended Flow Rate: 360 GPH (U.S.) (1,363 LPH)
Port Thread: 1-11 1/2 NPT
Height: 22 1/4 In. (565.2 mm)
Width: 25 In. (635 mm)
Depth: 12 1/4 In. (311.2 mm)
Weight: 46 lbs. (21 kg)
7
200 & 300 SERIES
DAHL FUEL/WATER SEPARATORS _________________________________________
WHY DAHL? PROVEN PERFORMANCE
Filters are a compromise wherever located. As a one-step strainer, DAHL diesel fuel/water separators have been tested and proven
a filter must be porous enough to allow sufficient flow volume. over millions of miles and hours under all sorts of conditions. Ask
This means the filters which came with the equipment are usually anyone who has used DAHL, or any Baldwin user, as Baldwin
in the 10-30 micron range. Filters makes DAHL products.
However, if a more efficient media were used, the filter would
become clogged very quickly, restricting the flow and resulting in MARINE DURABILITY
frequent, costly element changes. Marine units 75, 100-AL, 100-M, 100-M30, 150-AL, 150-M, 200-
Not only that, many fuel filters are not designed to remove AL, 200-M, 200-M30, 200-MMV, 200-MMV30, 300-AL, 300-M,
significant amounts of water, even though water is a primary cause 300-MM, 300-MM30, 300-MMV and 300-MMV30 have passed
of injector pump and nozzle damage. severe U.L. testing. Tests include fire endurance, vibration fatigue,
impact and thermal shock. These filters have also met U.S. Coast
Water and solid contaminants displace the diesel fuels lubricative Guard requirements for Marine Applications.
coating on precision injection components. The loss of this
protection results in wear, erosion, surface pitting and eventual fuel CLEAN FUEL
pressure loss.
DAHL eliminates nearly all of the engine problems caused by
THE SOLUTION water and solid contaminants in diesel fuel. In addition to saving
you the cost of expensive repair bills and aggravation, you can
DAHL’s functional dual chamber, 3-stage diesel fuel filter/water expect:
separators provide efficient suction side water separation and
contaminant filtration. The key is the unique DAHL patented • Longer Injection System Component Life
depressurizer cone, which spreads the flow of the fuel. The fact is, • Full Power Performance
the more area to flow over, the slower the flow and the greater the • Less Element Replacement Cost
separation of water and dirt from the fuel. DAHL diesel fuel
filter/water separators have less mechanical flow resistance SUPERIOR ENGINEERING
because the fuel changes direction only once. • Die Cast Aluminum
COMPLETE EFFICIENCY • Impact-resistant large transparent bowl
DAHL removes virtually 100% of the water and solid • Element service life is several times longer than
contaminants. conventional
• Easy to install, service and clean
• Positive air elimination
• Advanced spring design assures positive element seal
• Less mechanical resistance because of streamlined flow
path
BALDWIN LIMITED WARRANTY • B a ffle system is designed to stop emulsification and
disperse trapped air
Baldwin Filters warrants each new Baldwin or DAHL
• Ball check valve to stop reverse flow
Filter Product to be free from defects in workmanship and
• Six series specifically designed to fit diesel engines of
material as follows: various capacities
1. Housings one year from date of user’s purchase.
2. Electronics, Pumps and Motors 90 days from date of Authorized Dealer
user’s purchase.
3. Replaceable Elements, Spin-ons, Etc. during
equipment manufa c t u r e r ’s recommended filter service
interval, if properly installed in a Baldwin recommended
application.
Baldwin will replace or repair at its option, free of charge,
any part still in the Baldwin warranty period found by
Baldwin’s inspection to be defective when such product is
returned to place of purchase or to Baldwin Filters with
transportation charges prepaid.
Specifically excluded from this warranty is damage
resulting from excessive force, negligence, abuse, misuse,
misapplication, tampering, improper installation, fire or
accident. The warranty will not apply to any filter which
has been cut apart or subject to tampering. Also, damage to
plastic parts of fuel/water separators caused by the use of
fluids containing alcohol is not covered by this warranty.
Full details of this warranty are in the Policy and
Procedures Manual at the Baldwin or DAHL distributor or
may be obtained from Baldwin’s Service Engineering DAHL Products Division
Department.
Baldwin Filters
Kearney NE 68848-6010
(800) 822-5394