Baldwin Dahl 300 series Quick start guide

• Installation

• Operation

•Parts

• Service Information

HYDRAULIC OIL

RECYCLER MODELS

HYDRAULIC OIL RECYCLERS

PORTABLE UNITS

Portable units are mounted on a sturdy 46 inch high cart. Easy-rolling

10 inch wheels with rubber tires make it simple to wheel these units

to the equipment rather than bring the equipment to the unit.

110 Volt AC is standard, but 220 Volt AC is also available.

Maximum flow rate for single motorized units is 180 GPH (U.S.),

300 GPH (U.S.) for double units.

The motorized pump includes an on/off switch and 7 1/2 feet of

heavy-duty 16/3 cable with ground.

Units come with 15 foot lengths of number 10 or number 12 fuel

hoses. Number 10 fuel hoses come with 1/2” NPT male threaded

fittings and number 12 fuel hoses come with 3/4” NPT male threaded

fittings.

PIPE EXTENSION NOTE: For best suction control, a half-inch

by ten foot section of pipe can be attached to the end of the suction

hose. Notch the suction end of the pipe for good flow. If possible,

periodically move the location at the bottom of the tank.

Recycling ApplicAtions

with DAhl poRtAble Units _______

DAHL Hydraulic Recycler units are designed specifically for

removal of water from hydraulic oils. Due to the composition of

hydraulic oils, water becomes emulsified and cannot be removed

from the hydraulic oil by conventional methods. The DAHL

Hydraulic Recyclers use a special cartridge constructed from

filtering media that absorbs the water. Hydraulic oils that contain

relatively large amounts of water may require several passes

through the filter to remove the water. Since the cartridge captures

the water, the cartridge becomes more restrictive as it absorbs

water. To prevent undue wear on the pump and motor, a vacuum

switch is provided to shut the motor off when the pump produces a

predetermined suction.

DAHL HYDRAULIC RECYCLERS

The Hydraulic Recycler is available in two portable arrangements

and as an in-line filter. The portable units both consist of two units,

a pump, a motor, a control box and a vacuum switch. The “Series

Flow” model, 300-DHRAS5, has the double unit arranged so that the

hydraulic oil passes through the water-absorbing cartridge and then

through a synthetic media to achieve high capacity and fine filtering.

The “Parallel Flow” model, 300-DHRAP5, uses two water-absorbing

cartridges with the oil flow split between the two cartridges for

maximum water-absorbing capacity.

DAHL units are mounted on a convenient cart to be moved where

needed. Just position the unit in a convenient location where it can

be monitored occasionally for contaminant level.

OPERATION — RECYCLING

1. Priming

a. Loosen the T-Bolt handle to release the filter body from the

lid. Support the filter body with your hand prior to release.

b. Fill the filter body to within one-inch of the top with clean

diesel fuel.

c. Lubricate the lid cover gasket and replace.

d. Reinstall the body to the lid. Hand tighten only.

2. Turn unit on. The toggle switch is on the motor. All DAHL

units operate continuously and must NEVER be left running

dry (No fluid flow through the pump).

3. Recycling time is determined by the fuel quality or until no

additional contaminants appear in the bowl. Recycling time (in

hours or minutes) may be estimated with the use of Table 1.

4. Monitor the bowl for water and contaminants. Drain as needed.

NOTE: Water must be drained before the level reaches the

depressurizer cone. Refer to DRAINING WATER

section. An optional water sensor with automatic pump

shut-off is a handy accessory.

5. Element condition is monitored by the vacuum gauge located on

the DAHL filter outlet. Refer to ELEMENT REPLACEMENT

section.

Recyclers Flow Rates Table 1

Recycle Time

* Maximum Pump Rating - Actual flow may be less.

DAHL Gallons IN MINUTES IN HOURS

Model Per Divide Gallons Divide Gallons

Series Hour* of Fuel by of Fuel by

300 Double Series 300 5 300

When free water is found in the hydraulic oil, it will generally

be removed by the depressurizer cones found in the bowl. Other

contaminants that are large enough and dense enough will also be

removed by the depressurizer cones. For these reasons, the bowl

should be visually inspected from time to time. The bowl must

be drained before the level of water and contaminants reaches the

depressurizer cone.

A. Turn unit off.

NOTE: On units with automatic vacuum-activated shut-off,

the motor will shut off automatically when the pump

DRAining wAteR___________________________________________________

SERVICING

produces a predetermined suction. Drain replace

elements and press the reset button to resume operation.

B. Open the draincock up to 1/4 turn and drain all contaminants.

NOTE: If the contaminants will not drain out, slowly open the

primer plug on the lid to allow air to enter the system.

C. Close the primer plug and draincock.

D. Prime the system, if necessary. Refer to ELEMENT

REPLACEMENT section.

E. Start unit and check for leaks.

HYDRAULIC OIL RECYCLERS

SERVICING

A. When To Replace

The DAHL unit will shut off when the restriction of the filters

causes the pump to produce a predetermined suction. The

water-absorbing cartridge should be changed at this point.

B. How To Replace Water-Absorbing Cartridge

1. Turn on the override switch and check the vacuum reading.

Note the vacuum rating. Turn the unit off.

NOTE: If the hydraulic oil tank is above the DAHL unit, close the

shut-off valves or disconnect the DAHL unit to prevent oil

from flowing out of the DAHL body when disassembling.

2. Drain the body by opening the draincock. It may be necessary to

open the primer plug slightly to allow air to flow into the body.

Drain only enough oil to allow easier handling of the filter body.

3. Close the draincock and primer plug.

4. Loosen the T-Bolt handle to release the filter body from the lid.

(It is not necessary to completely remove the T-Bolt from the

wAteR-AbsoRbing cARtRiDge ReplAcement _____________________________

A. When To Replace

The synthetic element is a secondary filter and should not

become plugged as quickly as the water-absorbing cartridge.

The actual life will be dependent upon the filtering conditions.

B. How To Replace Synthetic Cartridge

1. Drain the body by opening the draincock. It may be necessary

to open the primer plug slightly to allow air to flow into the

body. Drain only enough oil to allow easier handling of the filter

body.

2. Close the draincock and primer plug.

3. Loosen the T-Bolt handle to release the filter body from the lid.

(It is not necessary to completely remove the T-Bolt from the

DAHL filter lids.) Support the filter body with your hand prior

to release.

synthetic cARtRiDge ReplAcement____________________________________

4. Remove the cartridge with a turning motion.

5. Inspect the ejector spring(s) at the bottom of the body. Also

check the centerpipe O-Ring and replace if hard or damaged.

6. Remove and replace the lid cover gasket. Be sure the lid groove

and body lip are clean. (Grease the lid cover gasket before

positioning.)

C. Reassembly

1. Lubricate the top and bottom cartridge gaskets. Install the

cartridge onto the centerpipe with a turning motion.

2. Fill the filter body with clean oil to within one inch of the

top.

3. Double check the lid cover gasket position in the lid groove.

4. Attach the body to the lid and hand tighten the T-Bolt handle.

5. Start unit and check for leaks.

DAHL filter lids.) Support the filter body with your hand prior

to release.

5. Remove the cartridge with a turning motion.

6. Inspect the ejector spring(s) at the bottom of the body. Also

check the centerpipe O-Ring and replace if hard or damaged.

7. Remove and replace the lid cover gasket. Be sure the lid groove

and body lip are clean. (Grease the lid cover gasket before

positioning.)

C. Reassembly

1. Lubricate the top and bottom cartridge gaskets. Install the

cartridge onto the centerpipe with a turning motion.

2. Fill the filter body with clean oil to within one inch of the

top.

3. Double check the lid cover gasket position in the lid groove.

4. Attach the body to the lid and hand tighten the T-Bolt handle.

5. Start unit and check for leaks.

Poor performance of the recycler or blender units is usually caused

by one or more of the following:

A. Air Leaks

1. Fittings. Insure the O-Rings on the fittings in the DAHL

filter ports are lubricated and not damaged, cracked or dirty.

NOTE: When using JIC 37° fittings, be sure only mating JIC

37° fittings are used. Misalignment will occur and air

leakage will result from an attempt to fasten a SAE 45°

fitting to a JIC 37° fitting. Check for fitting looseness,

seat dents, misalignment or unmatched threads. All

fittings must be wrench tight.

2. Bubbles In The Bowl. If bubbles appear at the depressurizer

cone, a leak is indicated between the tank and the inlet port.

NOTE: Old lines (rubber hose or metal tubing) may crack

when moved. Check areas around push-on fittings, pipe

adapters, hose clamps, etc. If air bubbles appear at the

draincock, check for particles stuck in the valve seat

or a partly open draincock. Also check for defective,

miscentered or unlubricated bowl gaskets. Check the

bowl plug O-Ring to make sure it is not cracked or

extruded out of place. The bowl plug should be hand

tightened only.

3. Gaskets. If the lid or bowl has been removed, make sure

the gasket grooves are clean. Inspect the gaskets for proper

seating in the grooves. Lubricate the gasket(s) with oil or

grease.

B. Clogging and Restriction

Lines. Check for collapsed lines caused by sharp bends or

excessive turns. Check the tank and/or filter shut-off valve(s).

2. Filter Elements. Early clogging can occur from badly

contaminated fuel or oil (micro-organism growth, rust,

sludge, dirt, etc). Always carry a spare DAHL element.

Asphaltinic materials (fuel oxidation products), which are

normally harmless to the injection system, can eventually

plug original equipment filters remaining in the fuel system.

If problems persist after the DAHL element has been

replaced, also replace the other fuel filter elements.

3. Filter Inlet. Severely contaminated fluids may cause inlet

plugging. In this event, close the tank supply shut-off valve

(if equipped) and disconnect the inlet line. Remove the bowl

and clean the inlet. Should the depressurizer cone also be

plugged, disassemble and clean out.

4. Bleed Back. If fuel in the DAHL filter bleeds back to

the fuel tank, an air leak or reverse flow valve problem is

indicated. Inspect lines and fittings first as indicated above.

If the reverse flow valve is clogged, use air or clean fluid to

flush out.

C. Motorized Pump Malfunction

Danger! Electric Shock Hazard. Only qualified

personnel should test or repair defective components.

1. Check the power source and on-off toggle switch for

operation.

2. On water-activated automatic shut-off models, drain the

water or select the override position on the switch.

D. Water Sensor Light Malfunction

NOTE: This is a 12 Volt DC low voltage system. There is no

danger of electrocution from the probes at the clear bowl

even though the current is switched on.

1. With the unit on, test the light by temporarily attaching a test

wire across the two probes at the clear bowl.

2. If the water level is above the probes and the light still does

not work, refer to PROBE CLEANING section.

TROUBLESHOOTING

HYDRAULIC OIL RECYCLERS

DAHL Model 300

*Standard with Unit Unless Stated.

4.0 in.

(101.6 mm)

Marine

Aluminum

T-Bolt

Nylon Gasket (Incl. in 200-GK)

Upper T-Bolt Seal (Incl. in 200-GK)

Lower T-Bolt Seal (Incl. in 200-GK)

Primer Plug

Primer Plug O-Ring (Incl. in 200-GK)

Lid Cover

Lid Cover Gasket (Incl. in 200-GK)

Centerpipe O-Ring (Incl. in 200-GK)

301*,-W,-30, Element w/Gasket

-MPG,-CS

Centerpipe

Body

Ejector Spring (4 required)

Ejector Spring Clip (4 required)

Reverse Flow Gasket

(Incl. in 200-DEPR KIT)

Reverse Flow Washer

(Incl. in 200-DEPR KIT & 200-GK

Reverse Flow Ball

(Incl. in 200-DEPR KIT)

Bowl Gasket (Incl. in 200-GK)

Depressurizer Set

(Incl. in 200-DEPR KIT)

200-21 Bowl

200-20 Bowl Ring

200-33 Socket Head Bolt

1/4-20 x 5/8 (8 required)

O-Ring (Incl. in 200-GK)

100-29 Bowl Plug

100-30 Draincock

{

Mounting Hole Pattern

Clearance for 3/8 In.

Diameter Fasteners

SPECIFICATIONS 300 DOUBLE

Flow Rate (Recommended) 300 GPH (U.S.) 1136 LPH

Height (w/o Cart) 22 1/4 in. (565.2 mm)

(w/Cart) 46 in. (1168 mm)

Width of Portable Units 26 in. (660 mm)

Depth of Portable Units 25 in. (635 mm)

Dry Weight, Portable Units 125 lbs. (57 kg)

Port Size — Inlet 1/2 in. NPT

Outlet 3/4 in. NPT

Sump Water Capacity 48 ounces

Filter Elements 301-W

MODEL 300 SPECIFICATIONS

REBUILD PROCEDURE

If it is ever necessary to dismantle the unit for inspection and/

or possible repairs, refer to the parts illustration. Then follow these

simple steps:

1. Refer to the appropriate ELEMENT REPLACEMENT steps

for disassembly. (Dismount if desired.)

2. Remove the socket head bolts from the bowl ring to release the

bowl. Stubborn bolts are easily removed by “shocking” the head.

Place the allen wrench into the bolt and lightly rap the wrench

with a hammer. Remove the bolt.

3. Unscrew the depressurizer cone to inspect the reverse flow valve.

Caution: Cone edges are sharp. Use gloves or a rag for protection.

4. Check all parts for damage. Replace all damaged parts or hard

gaskets. (Order Gasket Kit 200-GK.)

5. Refer to the parts illustration for reassembly. Clean all gasket

grooves and contact surfaces of foreign matter. Coat the lid

cover gasket with grease to hold in place before positioning and

coat all other gaskets and O-Rings with diesel fuel. Hand

tighten the depressurizer cone and wrench tighten the socket

head bolts.

6. Again, refer to ELEMENT REPLACEMENT section to finish

reassembly.

BALDWIN LIMITED WARRANTY

Baldwin Filters warrants each new Baldwin or DAHL Filter

Product to be free from defects in workmanship and material

as follows:

1. Housings one year from date of user’s purchase.

2. Electronics, Pumps and Motors 90 days from date of

user’s purchase.

3. Replaceable Elements, Spin-ons, Etc. during equipment

manufacturer’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 Department.

Baldwin Filters

Kearney NE 68848-6010

(800) 822-5394

WARNING: These products can expose you to chemicals, including Diisononyl Phthalate, Carbon black extracts, Nickel, 1,3 Butadiene, Ethylene Oxide, Epichlorohydrin, which are

known to the State of California to cause cancer, and Bisphenol-A, Ethylene Glycol, Ethylene Oxide, 1,3 Butadiene, Epichlorohydrin, which are known to the State of California to cause