T 20 Series Racor 500FG Turbine

User Manual: T-20 Series

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500FG Turbine Series

Fuel Filter/Water Separator

Contact Information

Parker Hannin Corporation

Racor Division

P.O. Box 3208

3400 Finch Road

Modesto, CA 95353

phone 800 344 3286

209 521 7860

fax 209 529 3278

racor@parker.com

www.racorcustomers.com

www.parker.com/racor

Instruction Part Number 15332 Rev E

The Racor 500FG Turbine Series

fuel filter/water separator protects

the precision components of

your engine from dirt, rust, algae,

asphaltines, varnishes and especially

water, which is prevalent in low

distillate fuels. Contaminants are

removed from fuel using the

legendary three stage process

described below.

How It Works

Stage 1 - Separation

Using the fuel flow, the stationary

turbine separates large solids and

free water through enchanced

centrifugal force.

Stage 2 - Coalescing

Smaller water droplets and solids

coalesce on the conical baffle and

fall to the collection bowl.

Stage 3 - Filtration

Engines will benefit from near 100%

water separation and fuel filtration

with Racor’s proprietary Aquabloc®

water repelling media. The

replaceable filters are available in 2,

10, and 30 micron ratings.

Mounting Instructions

Installation Diagram

Valve 1Valve 2

Fuel tanks above filter

head pressure should not

exceed maximum PSI of filter.

Fuel Tank

(Pressure Side Installation)

Install a shut-off valve when

fuel tank is higher than filter

Fuel tank below filter

Do not exceed 5’ (1.5m) of lift

or 4 inches of mercury (inHg)

of inlet piping restrictions

Fuel Tank

(Ideal Vacuum

Side Installation)

Fuel Tank

(Vacuum Side Installation)

Install a check valve

(with light or no restriction)

when tank is lower than filter

to maintain prime.

Pressure Side:

Fuel transfer pump not to exceed

maximum PSI or flow rate of filter.

Not ideal - pumps emulsify water

hindering filter performance.

Fuel transfer pump

(IDEAL vacuum side installation)

Engine

Maintain a clearance of at least 5

in. (12.7 cm) above and at least 2

in. (5.1 cm) below filter assembly

to service unit and drain bowl.

Valve 3

Suction (vacuum) Side:

Primary (first) filter - use 30 micron.

If it is the only filter in the system,

use 2 or 10 micron.

Optional Bypass Installation and Operation

(allows user to service filter without shutting down engine.)

Valves 123

Unit On-line Open Open Closed

Unit Off-line Closed Closed Open

500FG (Front)

4.0 in.

(10.2 cm)

7.5 in.

(19.1 cm)

4.5 in.

(11.4 cm)

3/8 in. (1.0 cm)

diameter clearance

for fasteners

V

± 10º

Install

500FG Assembly

within 10º of verticle

These customer supplied

materials should be on hand

before beginning installation.

Shop Towels•

Mounting Hardware •

Inlet/Outlet Fittings •

Fuel Hose •

Clean Diesel Fuel•

Parker Super O-lube or Clean •

Motor Oil

Thread Sealant •

(no thread tapes)

Positioning filter assembly:

Filter assemblies should be

installed on vacuum side of fuel

transfer pump for optimum

water separating efficiency.

See Installation Diagram.

Keep fuel line restrictions

to a minimum. Locate the

500FG filter assembly between

horizontal planes of bottom

of fuel tank and inlet of fuel

pump, if possible. If 500FG

filter assembly is installed in an

application where the fuel tank is

higher than filter, a shut-off valve

must be installed between the

tank and 500FG filter assembly

INLET. This will be used when

servicing the replacement filter.

Before installing filter assembly:

Obtain good ventilation and •

lighting.

Maintain a safe working •

environment.

Engine must be off for •

installation.

DO NOT smoke or allow open •

flames near installation.

Installing filter assembly:

Completely remove any vacuum

side filters in fuel line between

fuel tank and fuel pump. This is

where the Racor filter will mount.

Leaving these filters in place will

add to fuel line restriction. Filter

heads cast into engine or that are

non-removable or hard piped

should be serviced with a new

filter and left in place.

Keep fuel flow restriction

to a minimum. Always use

the maximum size fuel hose

possible. Do not make sharp

bends with flexible hose as kinks

may occur. Avoid use of two

45° elbow fittings where one 90°

elbow will work.

When routing hose, avoid

surfaces that move, have sharp

edges, or get hot (such as exhaust

piping).

Installation

Guidelines

Priming

The Unit

Draining Water:

Frequency of water draining is

determined by contamination

level of fuel. Inspect or drain

collection bowl of water daily

or as necessary. Collection

bowl must be drained before

contaminants reach top of

turbine or when Water Detection

Module (optional) indicates it’s

time to drain water.

Vacuum Applications /

Installations:

Close inlet valve (or valve #1) 1.

and open drain on bottom of

bowl with a suitable container

in place.

Close drain after all water 2.

and contaminants have been

evacuated – DO NOT leave

drain open too long as it will

eventually completely drain

entire filter assembly of water

AND fuel.

Follow Priming Instructions.3.

Pressure Applications /

Installations:

Open drain on bottom of 1.

bowl to evacuate water and

contaminants with a suitable

collection container in place.

Head pressure will push any

water and contaminants out

of drain while keeping filter

primed.

Close drain after all water 2.

and contaminants have been

evacuated – DO NOT leave

drain open too long as it will

eventually completely drain

entire filter assembly of water

AND fuel, and possibly drain

entire tank.

Service

Remove T-handle and lid 1.

from top of filter assembly.

Fill filter assembly with clean 2.

fuel.

Lubricate lid gasket and 3.

T-handle O-ring with clean

fuel or motor oil.

Replace lid and T-handle, 4.

tighten snuggly by hand only

– do not use tools.

If applicable, refer to 5.

equipment operator’s manual

to complete fuel priming

procedure.

Start engine, check for fuel 6.

system leaks. Correct as

necessary with engine off and

pressure relieved from filter

assembly.

Frequency of filter replacement

is determined by contamination

level of fuel. Replace filter

every 10,000 miles (16,000 km),

every 500 hours, every other oil

change, when vacuum gauge

(optional) reads between 7 to

10 inches of mercury (inHg),

if power loss is noticed, or

annually, whichever comes first.

Note – always carry extra

replacement filters as one tankful

of excessively dirty fuel can plug

a filter.

Use only genuine Racor

Aquabloc® replacement filters –

see Replacement Part List

All Applications:

Bypass filter assembly with 1.

bypass valves, if applicable.

Remove T-handle and lid.2.

Remove filters by holding bail 3.

handles and slowly pulling

upward with a twisting

motion. Dispose properly

according to local regulations.

Remove and discard old lid 4.

gasket and T-handle O-ring

and clean seal glands of any

dirt or debris. Lubricate new

gasket and seal (supplied with

new filter) with motor oil or

diesel fuel before installation.

Refer to Priming Instructions, 5.

otherwise, fill unit with clean

fuel, replace lid and T-handle

and tighten snuggly by hand

only – do not use tools.

Note - above ground tanks or

transfer pump applications

may use head pressure to

prime filter assembly.

Filter Replacement

A major cause of power loss or

hard starting is result of an air

leak (or clogged filter). If your

unit will not prime or fails to

hold prime, check that drain,

Troubleshooting Procedures

bowl and filter are properly

tightened. Next, check all fitting

connections and ensure fuel

lines are not pinched or clogged

with contaminants. If problems

persist (and filter is new) call

Racor Technical Support for

assistance: (800) 344-3286 or

(209) 575-7555.

500FG

Maximum Flow Rate: 60 GPH (227 LPH)

Port Size 3/4´´-16 UNF

(SAE J1926)

Service Clearance

Above Assembly

Below Assembly

5.0 in. (12.7 cm)

2.0 in. (5.1 cm)

Replacement Filters

2 micron

10 micron

30 micron

2010SM-OR

2010TM-OR

2010PM-OR

Water In Bowl Capacity 3.7 oz. (109 ml)

Height 11.5 in. (29.2 cm)

Width 5.8 in. (14.7 cm)

Depth 4.8 in. (12.2 cm)

Weight (dry) 4.0 lb (1.8 kg)

Max. Working Pressure 25 PSI (1.7 bar)

Clean Pressure Drop 0.25 PSI (1.7 kPa)

Water Removal Efficiency 99%

Ambient Temp. Range -40°F to +250°F (-40°C to +121°C)

Max. Fuel Temperature 190°F (88°C)

Specifications

Part Number Description

1RK 11888 T-handle and O-ring Kit (9/16”-18 UNF Threads)

Hand Tighten

1a 11350 T-handle O-ring

2RK 15078 (FG) Lid Kit

2a 15005 Lid Seal

B

2010SM-OR (2 micron),

2010TM-OR (10 micron), or

2010PM-OR (30 micron)

Replacement Filter (All Models)

C

RK 15383-01 Heater Kit (12 vdc, 300 watt)

RK 15383-02 Heater Kit (24 vdc, 300 watt)

3RK 15081 Bowl Fasteners (4) Tighten to 60 in. lbs (6.78 Nm)

4RK 15035 (FG) Bowl Ring Kit

5RK15405 (FG >2002)

RK 15279-01 (FG <2002)

Clear Bowl Kit (includes 5, 5a, 9, 9a, 11, & 11a)

Clear Bowl Kit (includes 5*, 5a, 11, & 11a)

5a 15374 Bowl Seal

6RK 15013D Turbine Centrifuge and Conical Baffle Kit

Hand Tighten

7(not sold seperately) Check Ball Seal

8RK 15010B Check Ball Kit (includes 7)

9 RK 30476 (FG >2002) Self-venting Drain Kit Tighten to 30 in. lbs (3.39 Nm)

9a (not sold seperately) Drain Gasket

10

RK 21067 Heater Feedthru Kit Tighten to 15 in. lbs (1.69 Nm)

RK 11-1679 Feed-thru Plug Kit Tighten to 15 in. lbs (1.69 Nm)

10a 43506 Feedthru or plug O-ring

11

RK 21069 Water Probe Kit Tighten to 15 in. lbs (1.69 Nm)

RK 20126 (FG) Bowl Plug Kit Tighten to 15 in. lbs (1.69 Nm)

11a (not sold seperately) Water Probe or Plug O-ring

12 RK 11780 (FG <1993) Drain Assembly Kit

12a

12b

12c

(not sold seperately)

(not sold seperately)

(not sold seperately)

Drain Seal (Finger)

Drain Body O-ring

Drain O-ring

13 RK 30488 (FG 1994-2002) Drain Assembly

9a

12b

(not sold seperately)

(not sold seperately)

Drain Gasket

Drain Body O-ring

D

RK 15378 (FG) Clamp Bracket Kit

RK 11838 Carraige Bolt Kit

E(not sold seperately) 500 Body/Housing

1

2

2a

B

D

7

8

5

4

1a

6

5a

10a

3

C

9a

E

11a

11

9

10

Parts and kits listed can be purchased from a Racor distributor.

Go to www.racorcustomers.com for a distributor near you.

5*

12b

12a

12c

13

5*

12b

9a

12

RK 11780 Drain Kit

(1993 & Older)

11 11

11a

11a

Drain Configurations

RK 30488 Drain Kit

(1994-2002)

5

9a

11a

11

9

RK 30476 Drain Kit

(2002-Current)

Specifications RK 11-1969

Application For 500 Filter Assemblies

Thread Size 1/4˝ NPT bottom boss mount

Fitting Thread 9/16˝-18 UNF

Dimensions 2.0˝ Diameter x 1.1˝ Depth

Weight (dry) 0.3 lb (0.1 kg)

Ambient Temperature Range -40o to +250oF (-40o to +121oC)

Special Notes: For severe vibration applications, mount gauge on a stable, remote location and

connect to the source using flexible tubing. After September 1999, Racor converted many liquid-

filled gauges to new silicone dampened movement. This new (dry) technology provides a vibration

resistant design that never leaks fluid or requires adjustments due to temperature or altitude

variations.

The T-handle vacuum gauge

monitors your filters condition.

As your filter slowly becomes

clogged with contaminates,

restriction (resistance to flow)

increases. Because of this

restriction, more air is mixed

with fuel and less fuel is

delivered to the engine (fuel de-

gassing). This will result in loss

of power and eventually stall the

engine.

Installing a T-handle vacuum

gauge in your fuel system gives

you a visual monitor of your filter

condition. Excessive resistance

on the gauge means it’s time to

change the filter.

T-handle Vacuum Gauge

July 2010© Parker Hannin Corporation

All products manufactured

or distributed by Racor are

subject to the following, and

only the following, LIMITED

EXPRESS WARRANTIES, and

no others: For a period of

one (1) year from and after

the date of purchase of a new

Racor product, Racor warrants

and guarantees only to the

original purchaser-user that

such a product shall be free

from defects of materials

and workmanship in the

manufacturing process. The

warranty period for pumps and

motors is specifically limited

to ninety (90) days from date of

purchase. A product claimed to

be defective must be returned

to the place of purchase. Racor,

at its sole option, shall replace

the defective product with a

comparable new product or

repair the defective product.

This express warranty shall be

inapplicable to any product not

properly installed and properly

used by the purchaser-user

or to any product damaged or

impaired by external forces.

THIS IS THE EXTENT OF

WARRANTIES AVAILABLE

ON THIS PRODUCT. RACOR

SHALL HAVE NO LIABILITY

WHATSOEVER FOR

CONSEQUENTIAL DAMAGES

FLOWING FROM THE USE OF

ANY DEFECTIVE PRODUCT

OR BY REASON OF THE

FAILURE OF ANY PRODUCT.

RACOR SPECIFICALLY

DISAVOWS ALL OTHER

WARRANTIES, EXPRESS

OR IMPLIED INCLUDING,

WITHOUT LIMITATION, ALL

WARRANTIES OF FITNESS

FOR A PARTICULAR PURPOSE

(EXCEPT FOR THOSE WHICH

APPLY TO PRODUCT OR

PART THEREOF THAT IS

USED OR BOUGHT FOR USE

PRIMARILY FOR PERSONAL,

FAMILY, OR HOUSEHOLD

PURPOSES), WARRANTIES OF

DESCRIPTION, WARRANTIES

OF MERCHANTABILITY,

TRADE USAGE OR

WARRANTIES OR TRADE

USAGE.

Warning

Failure or improper selection

or improper use of the

products and/or systems

described herein or related

items can cause death,

personal injury and property

damage. This document and

other information from Parker

Hannifin Corporation, its

subsidiaries and authorized

distributors provide product

and/or system options for

further investigation by users

having technical expertise.

It is important that you

analyze all aspects of your

application and review the

information concerning the

product or system in the

current product catalog. Due

to the variety of operating

conditions and applications

for these products or systems,

the user, through its own

analysis and testing, is solely

responsible for making the

final selection of the products

and systems and assuring that

all performance, safety and

warning requirements of the

applications are met.

The products described

herein, including with

limitation, product features,

specifications, designs,

availability and pricing, are

subject to change by Parker

Hannifin Corporation and

its subsidiaries at any time

without notice.

The following statement

is required pursuant to

proposition 65, applicable

in the State of California:

‘This product may contain a

chemical known to the State of

California to cause cancer or

reproductive toxicity’.

Limited Warranties Statement