Baldwin DAHL 55-EK Installation Manual

DAHL 55-EK and 85-EK In-Filter Heater Kit Installation
For Retrofitting Models 100, 150, 200 & 300 Series with Heater
MATERIALS NEEDED
In addition to the furnished parts, an appropriate length of
gauge electrical wire and a 10A 12V in-line fuse assembly is
needed. (Use 10A fuse for 24V.)
55-EK & 85-EK RETROFIT ASSEMBLY
(DAHL diesel fuel filter/water separators with an -H suffix
come already assembled.)
1. If installing the kit in an used unit, drain and remove the DAHL
body assembly.
2. Disassemble the body assembly.
a. Remove the filter element.
b. Remove the socket head bolts around the bowl ring. Lift off
the bowl ring, then the clear bowl.
3. Install the heater element into the body assembly:
For 55-EK on Models 100 & 150 Series
a. Place the heater band into the body with the wire lead side
down. The heater band fits within the wall of the unit body.
b. Run the lead wires through one of the 3/8 inch flow holes at
the bottom of the body and then through the depressurizer
set.
c. Gently push the heater band into the body.
For 85-EK on Models 200 & 300 Series
a. Place the heater element wafer into the body with the wire
lead side up. The center hole of the heater element fits
around the centerpipe in the unit body.
b. Bend the wire down at the heater element wafer notch,
then run it through one of the 3/8 inch flow holes at the
bottom of the body and then through the depressurizer
set.
c. Align the holes in the heater element wafer with the ejector
springs and gently push the element to the bottom of the
body.
Included with 100-H, 150-H & 200-H
LEAD WIRE CONNECTIONS
16 1. Connect the lead wire to the clear bowl.
a. Make sure the bowl ring is around the clear bowl before
installing the bolts. (It will not fit over the bolts after they
are installed.)
b. Insert the #8-32 bolts through the terminals of the heater
wire leads. Secure the terminal with one #8 nut. (Note: Be
sure the terminal's flush side is facing the bowl.)
c. Secure the #8-32 bolts to the clear bowl. Be sure the
O-Ring is between the outside of the bowl and the flat
washer.
2. Reassemble the new clear bowl to the filter body and reinstall
the body assembly. (Note: Replace and grease the bowl
gasket.)
ELECTRICAL HOOKUP
1. Install the toggle switch. Drill a 31/64 inch hole in the desired
location.
2. Connect the wire to a 12 volt power source capable of
delivering 10A. (Use 16 gauge wire.) (Note: 24V systems use
10A fuses.)
a. Splice the 10A fuse assembly to the 16 gauge wire between
the power supply and the toggle switch. Position the fuse
assembly for accessible servicing.
b. Connect the other end of the 16 gauge wire to the power
terminal of the toggle switch with a female quick disconnect
terminal. (One for each toggle switch is included.)
3. Connect the ground wire. Use a second length of 16 gauge
wire to ground the terminal of the toggle switch. Connect the
other end to a suitable ground such as the engine block or
steel frame.
4. Connect the third length of the 16 gauge wire to the "ACC"
terminal of the toggle switch. Insert the other end into one
of the 90° insulated connectors. Plug the 90° insulated
connector into one of the heater terminal #8-32 bolts.
5. Plug the remaining 90° insulated connector to the second
heater terminal #8-32 bolt. Find suitable ground for the other
end of the wire.
The toggle switch should light up when the heater is on.