Racor_Installation_I.. - University of St Andrews
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1. 4 Review some of the workings of the units below to possibly uncover other solutions Correct Application It is very important that the FH filter assembly is not under specified for the application The maximum fuel flow rating of the FH filter assembly must not be exceeded Doing so will reduce efficiency and de gas pull air from the fuel Filter Elements Replacement elements are available in 2 10 and 30 micron ratings Filtration needs are based on application fuel quality maintenance schedules and operating climates A simple rule to remember is the finer the filtration the more frequent the filter change Always carry extra replacement elements with your equipment as one tankful of excessively contaminated fuel can plug an element When clogged to the maximum capacity elements will have a brown to black color or tar like contaminants may be present this is normal An appearance of a multi colored slime which may have a foul odor is an indication of microbiological contamination This condition must be treated immediately Severe conditions must be corrected by a repair facility Note Never operate the filter assembly without the element in place the element safety valve will not expose the outlet hole on the fuel return tube if the element is removed Instead punch the emergency tab on the top of the element and leave in place Puncturing the emergency tab will bypass all filtration and send unfiltered fuel to your engin2. 5 PSI Maintain a clearance above the filter assembly E of at least 5 12 7 cm for the 900FH and 10 25 4 cm for the 1000FH for element removal A shut off valve is recommended v when the fuel tank is mounted gt higher than the filter P L Fuel Tank Outlet Ideal Vacuum Side Installation t Acheck valve with light to no A Optional fuel transfer pump restriction is recommended not to exceed 15 PSI 103 to enable the system to Q kPa or maximum flow rate of maintain prime the filter NOT ideal pumps emulsify water hendering L filter performance f Fuel Transfer Pump IDEAL vacuum side installation Maintain a clearance below the filter assembly of atleast 2 5 1 cm M a for draining and servicing the bowl Fuel Tank Vacuum Side Installation Valve 3 L n ee ee ee M f Optional Bypass Installation and Operation Fuel Tanks Below the Filter The optional bypass installation allows the user to Do not exceed 5 1 5 m of lift or 4 inches service the filter without shutting down the engine of mercury inHg of inlet piping restriction Valves 1 2 3 Unit On line Open Open Closed Unit Off line Closed Closed Open Racor Plated Steel Fittings T1 Tube or ae 9010 10 8 9010 10 10 9020 10 8 9020 10 10 911 010 F8 911 010 F12 913 010 H8 913 010 H10 913 010 H12 911 010 H8 911 010 H10 911 010 H12 Note T1 is the side of the fitting that will at
3. 900FH and 1000FH Turbine Series Fuel Filter Water Separators Installation Operation and Service Information Overview The 900FH and 1000FH Turbine Series filter assemblies protect precision engine components from dirt rust algae asphaltines varnishes and especially water which is prevalent in engine fuels They remove contaminants from fuel using the following legendary three stage process Stage 1 Separation As fuel enters the assembly it moves through the centrifuge and spins off large solids and water droplets which are heavier than fuel and fall to the bottom of the collection bowl Stage 2 Coalescing Small water droplets bead up on the surface of the conical baffle and cartridge element When heavy enough they too fall to the bottom of the collection bowl Stage 3 Filtration Proprietary Aquabloc Il cartridge elements repell water and remove contaminants from fuel down to 2 micron Aquabloc II cartridge elements are waterproof and effective longer than water absorbing elements Turbine Series filter assemblies are designed to be installed on the vacuum side of the fuel transfer pump for best efficiency see the Installation Diagram on page three Adjustable one piece clamp type mounting brackets with grade 5 fasteners are included for ensured durability The 900FH uses one mounting bracket and the 1000FH uses two The see thru contaminant collection bowl allows the operator to check for water and solid c
4. C Remove the heater and repeat the above test Troubleshooting All Racor FH filter assemblies are 100 tested to ensure a leak proof quality product Note Correct external fuel leaks immediately In the event difficulties are experienced with your filter assembly or a problem appears to prevent the engine from running smoothly follow the quick help illustration below or refer to the procedures on the previous page Note Apply Parker Super O lube part number RK 31605 or equivalent to all seals at major attachment points to maintain integrity seal elasticity to fill small voids and provide protection from degradation Perform the following checks with the engine OFF and applicable valves closed For replacement parts refer to the Replacement Parts section of this manual Damaged worn or dirty seals will allow air ingestion Inspect and replace all seals as needed Clean the sealing surfaces of dirt or debris every time the elementis replaced Hand tighten the T handle eee only Do not use tools If the element is changed or the assembly drained for any reason repriming the assembly filling with fuel may be necessary Fill to just above the top of the element before replacing the lid If the carriage bolt has been we 7 loosened do not overtighten it as this may distort the cylinder roundness The four self tapping capscrews must not be overtightened to avoid stripping out the body threads After disassembly sta
5. M OR 2020SM OR 10 micron 2040TM OR 2020TM OR 30 micron 2040PM OR 2020PM OR Minimum Service Clearance Above assembly 5 in 127 mm 10 in 254 mm Below assembly 2 in 61 mm 2 in 51 mm 15 PSI 109 kPa 15 PSI 103 KPa Available Options 2 Water Sensor Yes Yes Heater Yes Yes Operating Temperature 40 to 255 F 40 to 121 C Special Notes 1 Pressure installations are applicable up to the maximum PSI shown Vacuum installations are recommended 2 Not for use on gasoline applications Troubleshooting Note Correct external fuel leaks immediately These conditions will result in reduced engine performance such as hard starting stalling reduced power and other associated problems New filter installations must be filled with fuel and the fuel system must be adequately primed following the engine manufacturer s recommendations if applicable Existing installation difficulties are usually associated with improper priming procedures or damage to the unit or fuel system The result is either internal air suction or external fuel leakage Diagnosis should be in the following steps 1 Check the fuel tank level and make sure any fuel delivery valves are in the open position as applicable 2 Ensure the T handle bowl fasteners and fuel fittings are tight Also verify that the bowl drain is closed 3 Ifthe Racor element is new check potential restriction at the fuel tank draw tube An in tank strainer may be plugged
6. WING 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 ALLWARRANTIES OF FITNESS FORA 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
7. ate both seals with motor oil or diesel fuel before installation 5 Refer to Priming Instructions otherwise fill the unit with clean fuel then replace the lid and T handle and tighten snugly by hand only do not use tools Note above ground tanks or transfer pump applications may use head pressure to prime the filter assembly Installing Optional Water Detection Components Note Racor electrical options are for use with diesel applications only Water Sensor FH filter assemblies can be ordered with a water sensor installed at the factory The following instructions are for FH filter assemblies that do NOT have a water sensor already installed All water sensors must be used with a special Racor electronic detection module to function properly Due to the variety of detection modules available they are sold separately and installation instructions are supplied with each kit See chart below for part numbers and descriptions Drain the FH filter assembly completely Take out the water sensor plug on the side of the bowl and discard properly Lubricate the water sensor O ring with Parker Super O lube or equivalent Thread the water sensor into the probe port on the side of the bowl Tighten snugly Attach the Racor detection module to the wire leads of the water sensor Specific instructions for this step are included with each detection module Prime the FH filter assembly by filling with fuel Start engine and check for leaks Co
8. be 1000FH Return Tube Body Clamp Bracket 2 Micron Element w Seals 10 Micron Element w Seals 30 Micron Element w Seals 2 Micron Element w Seals 10 Micron Element w Seals 30 Micron Element w Seals Valve Spring amp O ring Kit 12 vdc Heater w Body Feed thru 24 vdc Heater w Body Feed thru Body Feed thru Assy for heater Body Feed thru Plug not shown Square Cut Gasket Lid and Bowl Checkball and Seal Turbine Centrifuge Conical Baffle See thru Bowl w Drain amp Plug Water Sensor Water Sensor Plug Body 7 8 14 Racor Diesel Biocide ot 16 oz bottle Bowl Ring 5 Diameter Capscrew Kit 4 Self venting Drain FH Assembly Seal Kit Parker Super O lube Racor Additives see chart on next page ADT 2116 16 oz Bottle 1 280 Gallons Concentrated formula Diesel Biocide Kills bacteria and fungi ADT 2201 1 Gallon Bottle 10 240 Gallons Pravanieconesion Diesel ADT 1116 16 oz Bottle 320 Gallons Enhances engine performance Conditioner Stabilizes the fuel Plus ADT 1201 1 Gallon Bottle 2 560 Gallons e Quieter engine operation ADT 4116 16 oz Bottle 128 Gallons Inhibits waxing icing and gelling Protects down to 30 F 34 C ADT 4201 1 Gallon Bottle 1 024 Gallons Enhances engine performance Specifications Basic Models o m O oo O Maximum Flow Rate 90 GPH 341 LPH 180 GPH 681 LPH Port Size SAE J1926 7 8 14 UNF 7 8 14 UNF Replacement Elements 2 micron 2040S
9. d PATER SEPARATOR a Plastic enclosure measures 2 75 by en 1 0 by 1 5 Power draw is 10 milliamps ie Installing An Optional Fuel Heater Note Racor electrical options are for use with diesel applications only The in filter heater is a cold weather starting aid with an internal automatic thermostat that turns the heater ON when the fuel temperature drops below 50 F 10 C and turns OFF when the fuel reaches 80 F 27 C Heat is supplied in the FH filter assembly just below the replacement element to melt wax crystals and allow fuel to pass through the element for quick easy starting The 300 watt heater is available in 12 or 24 vdc and is operated by turning the ignition switch ON for a minimum of five minutes prior to starting the engine FH filter assemblies can be ordered with a heater installed at the factory If you are adding a heater to a filter assembly that does not already have one refer to the installation instructions that come with the heater Follow the directions below to hook up the heater wire leads to your engine Customer Supplied Items 1 Heater power demand is 25 amps for 12 vdc and 13 amps for 24 vdc Due to the power demand an additional relay is recommended for the safest method of installation Racor offers two relay kits available from your Racor distributor Part numbers are RK 11861 for 12 vdc and RK 11862 for 24 vdc These kits include an in line fuse holder and fuse and the RK 11862 kit al
10. e Service the element as soon as possible to avoid harmful contaminants flowing downstream to the engine Water Sensors This feature alerts the operator of a high water condition The bowl is then drained of water at the earliest convenience Note a Racor water detection module is needed to work with the in bowl sensor The unit should activate when the water reaches the sensor tips and when they measure between 47 000 and 100 000 ohms of resistance depending on the detection module used If not the tips may be fouled with a coating Remove the sensor and clean the tips with a cloth Run a jumper wire between the tips with the ignition ON to test the system Difficulties usually lie in the wire connections power source or an independent ground Heaters In filter heaters are starting aids only but may be left on during cold operations The 300 watt heater is an extremely reliable option but MUST be powered via a relay switch due to the initial amperage surge at start up 25 amps at 12 vdc and 12 5 amps at 24 vdc They do not activate unless the fuel is below 50 F 10 C and automatically deactivate at 80 F 28 C Heater Testing he heater can only be tested when the thermostat is closed fuel temperature is below 50 F or 10 C With a voltmeter attached to external wiring and engine off power should drop when heater is switched on Option remove the heater and place it in a freezer until the temperature is under 50 F 10
11. e it gets to this level Awater sensor plug is installed ifthe water sensor option is not selected Tighten snugly Specification 15 20 in lbs The water sensor if equipped should activate when water contacts the tips Air bubbles or fuel leakage appearing from the sensor may indicate that the it is loose or that the O ring is damaged Tighten or disassemble and inspect Specification 15 20 in lbs RACOR LIMITED WARRANTIES STATEMENT 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 FLO
12. fuel tank and the inlet of the fuel pump if possible Ifthe FH filter assembly is installed in an application where the fuel tank is higher than the filter a shut off valve must be installed between the tank and the FH filter assembly INLET This will be used when servicing the replacement element Before installing the filter assembly e Obtain good ventilation and lighting e Maintain a safe working environment e The engine must be off for installation e DO NOT smoke or allow open flames near the installation Installing the filter assembly e Completely remove any vacuum side filters in the fuel line between the fuel tank and the fuel pump This is where the FH filter assembly will mount Leaving these filters in place will add to the fuel line restriction Filter heads cast into the engine or that are non removable or hard piped should be serviced with a new element and left in place e Keep fuel flow restriction values to a minimum Always use the maximum size fuel hose possible Do not make sharp bends with flexible fuel hose as kinks may occur Avoid the use of two 45 elbow fittings where one 90 elbow will work When routing hose avoid surfaces that will move have sharp edges or will get hot Such as exhaust piping 900FH and 1000FH Installation Diagram A Vacuum Side Installation is Recommended Fuel Tanks Above the Filter Fuel Tank LMM Do not exceed 39 11 9 m Pressure Side Installation of head feet or 1
13. it will eventually completely drain the entire filter assembly of water AND fuel 3 Follow Priming Instructions Pressure Applications Installations 1 Open the self venting drain on the bottom of the bowl to evacuate water and contaminants with a suitable collection container in place Head pressure will push any water and contaminants out of the drain while keeping the filter primed 2 Close the drain after all the water and contaminants have been evacuated DO NOT leave the drain open too long as it will eventually completely drain the entire filter assembly of water AND fuel and possibly drain the entire tank Element Replacement Frequency of element replacement is determined by the contamination level of the fuel Replace the elements every 10 000 miles every 500 hours every other oil change when the vacuum gauge optional reads between 6 to 10 inches of mercury inHg if power loss is noticed or annually which ever comes first Note always carry extra replacement elements as one tankful of excessively dirty fuel can plug a filter Use only genuine Racor Aquabloc Il replacement elements All Applications 1 Bypass filter assembly with bypass valves if applicable 2 Remove the T handle and lid 3 Remove the element by holding the bail handles and slowly pulling upward with a twisting motion Dispose of properly 4 Replace old lid gasket and T handle O ring with new seals Supplied with new element Lubric
14. ontamination at a glance Getting Started The following customer supplied materials should be on hand before beginning installation e Shop Towels e Diesel Fuel about 1 gallon e Thread Sealant no thread tapes e Parker Super O lube or equivalent e Fuel Hose see Fuel Hose chart on page 4 e Mounting Hardware 3 8 or M10 fasteners e inlet Outlet Fittings see Fitting chart on page 4 ROCOR Parker Hannifin Corporation Racor Division PO Box 3208 3400 Finch Rd Modesto CA 95353 USA 209 521 7860 800 344 3286 www parker com racor e mail racor parker com Filtration 1 l i k E oie je 1000FH Mounting Information no scale 1000FH Clearance for 3 8 M10 fasteners Clearance for 3 8 M10 fasteners 11 0 27 9 cm Adjustable to 13 5 _ eT noe Brackets are 34 3cm adjustable from 2 0 to a 8 8 5 1 to 22 4 cm 10 10 Note mount the filter assembly as close to vertical V as possible Do not exceed 10 from vertical or the assembly may not function properly 90 Installation Instructions When positioning the filter assembly e FH filter assemblies should be installed on the vacuum side of the fuel transfer pump for optimum water separating efficiency See Installation Diagram on the next page e Keep fuel line restrictions to a minimum Locate the FH filter assembly between the horizontal planes of the bottom of the
15. rrect as necessary a oe a N D Water Detection Modules Racor water detection modules are available in a wide selection for various installation requirements Under dash in dash and remote mount these solid state units may be used with any Racor water sensor They are manufactured using the highest quality materials and are all 100 electronically tested An electronic detection module analyzes electrical resistance at the water sensor and determines if water is present If so the detection module operates to indicate water based on its features listed below All units reset automatically after water is removed unless specified Below are some of our more popular modules others are available Under dash mount Light and audio Illuminates and sounds when water is RK 12870 detected Plastic enclosure measures 1 4 square by 1 25 deep Power draw is 1 milliamp In dash mount Light and audio Red DRAIN lamp illuminates continuously jon and horn sounds momentarily when y water is detected Initial power up self __ Fuck Tana Bpeure diagnosis feature and circuit protection TA included Plastic 2 gauge Power draw is 3 milliamps for 12 vdc and 13 milliamps for 24 vdc Under dash mount Light only Green ON lamp illuminates with power and red i DRAIN lamp illuminates when water is a Mi ry RK 20725 detected Initial power up self diagnosis RACOR ae feature and circuit protection include
16. rt threads by hand prior to using tools Specification 55 65 in lbs gt LE The hollow aluminum check ball floats up against the seal when the fuel is stopped thus preventing fuel bleed back If your unit looses prime inspect upstream hose connections first otherwise disassemble the unit and inspect the seal and ball Air bubbles or fuel leakage appearing from the drain may indicate that the drain is not closed completely or that the seal has been clogged with contaminants Lo Tighten or disassemble and inspect Specification 30 35 in lbs If the self venting drain will not work when opened it may be clogged Cycle the drain open close or attach a hose and briefly apply air lt 2 3 PSI to dislodge the contaminants The element should be replaced every 10 000 miles every 500 hours every other oil change annually or at the first indication of power loss whichever occurs first For Construction and Agricultural use change the filter every 300 hours See Heaters on previous page SAE O ring ports should have a smooth angled seat for sealing Do not scratch this surface Check O ring for damage The heater feed thru O ring must not be damaged or mE lt swollen Tighten snugly hee Specification 15 20 in lbs Air bubbles appearing from the turbine are an indication of an upstream leak between the Racor inlet and the fuel tank pick up tube Drain water if present befor
17. so includes a resistor Use the 25 amp fuse with a 12 vdc system and the 15 amp fuse and resister with a 24 vdc system 2 An ON OFF toggle switch may be used to control power to the heater relay This allows the operator to cut power to the heater relay during summer use 3 All wires should be 14 AWG American Wire Gauge minimum Installation 1 Either heater wire may be used for Hot or Ground 2 Wire terminal connections should be soldered and crimped 3 Run wires in protected locations Avoid hot surfaces and places that could pinch or rub on the wires Manual ON OFF Switch Optional Fuse Block a Relay B2 C4 1 Amp ad E3 Ad Fuse Fuse ES i 7 E Ignition 4 Switch Battery Use a resistor and 15 amp fuse with 24 vdc heaters Replacement Parts Part Number 1 RK 11 1945 11350 2 RK 11 1927 01 11007 3 RK 19002 03 RK 11021 03 4 RK 11 1931 RK 11 1930 5 RK 11815 103 6 900FH 2040SM OR 2040TM OR 2040PM OR 1000FH 2020SM OR 2020TM OR 2020PM OR 7 RK 11 1953 8 RK 11 1800 01 RK 11 1800 02 9 RK 21067 RK 11 1679 10 11007 11 RK 11028B 12 RK 11 1939 13 RK 11 1938 14 RK 32204 RK 22838 15 RK 11 1776 16 RK 11037A 17 RK 11542 18 RK 30476 Additional Parts RK 11 1952 RK 31605 various Description T handle and O ring Kit T handle O ring Lid and Lid Gasket Kit Square Cut Gasket Lid and Bowl 900FH Outer Cylinder 1000FH Outer Cylinder 900FH Return Tu
18. tach to the FH filter housing Additional fitting options may be available from a Parker dealer Call 1 800 C PARKER 1 800 272 7537 for the dealer nearest you SAE O ring T1 to JIC 37 Male Flare T2 Elbow SAE O ring T1 to JIC 37 Male Flare T2 Straight SAE O ring T1 to Female NPT T2 Straight SAE O ring T1 to Hose Barb T2 Elbow SAE O ring T1 to Hose Barb T2 Straight Racor Fuel Hose Racor fuel hose is fire resistant and meets SAE J1527 Type A class and SAE J1942 standards This hose delivers test proven performance in a wide operating temperature range constant working pressure in popular sizes long lasting reinforced construction kink and cut resistance and 7 8 14 UNF 7 8 14 UNF 7 8 14 UNF 7 8 14 UNF 7 8 14 UNF 7 8 14 UNF 7 8 14 UNF 7 8 14 UNF 7 8 14 UNF 7 8 14 UNF 7 8 14 UNF 7 8 14 UNF compatibility with a variety of standard fittings 3 4 16 UNF 7 8 14 UNF 3 4 16 UNF 7 8 14 UNF 1 2 14 NPT 3 4 14 NPT 1 2 Hose Barb 5 8 Hose Barb 3 4 Hose Barb 1 2 Hose Barb 5 8 Hose Barb 3 4 Hose Barb Part Number HoseID Working Pressure Min Bend Radius CGH 10 1 2 125mm 500 PSI 3 5 MPa 2000 PSI 14 MPa 21 4 55 mm 5 8 16mm 500 PSI 3 5 MPa 2000 PSI 14 MPa 2 3 4 70 mm CGH 16 7 8 22mm 500 PSI 3 5 MPa 2000 PSI 14 MPa 3 1 2 90 mm Note addi
19. tional sizes are available call Racor at 1 800 344 3286 Additional Features e High tensile steel wire braid e No Skive does not require the removal of outer cover to install e USCG rated for gasoline diesel lube oil and hydraulic systems e Working temperature of 4 F to 212 F 20 C to 100 C Priming Instructions Remove the T handle and lid from the top of the filter assembly Fill the filter assembly with clean fuel Lubricate lid gasket and T handle O ring with clean fuel or motor oil Replace the lid and T handle and tighten snugly by hand only do not use tools lf applicable refer to the equipment Operator s Service Manual to complete the fuel priming procedure Start engine and check for fuel system leaks Correct as necessary with engine off and pressure relieved from filter assembly gt OO DO Service Instructions Draining Water Frequency of water draining is determined by the contamination level of the fuel Inspect or drain the collection bowl of water daily or as necessary The collection bowl must be drained before contaminants reach the top of the turbine or when the Water Detection Module optional indicates it s time to drain water Vacuum Applications Installations 1 Close the inlet valve or valve 1 and open the self venting drain on the bottom of the bowl 2 Close the drain after all the water and contaminants have been evacuated DO NOT leave the drain open too long as
20. 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 and reproductive toxicity Racor s policy is one of continual improvement in design and manufacturing to insure still finer products therefore specifications equipment and product information while correct at the time of publication is subject to change without notice Copyright Parker Hannifin Corporation July 2003 Part Number 12960 Revision A
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