Ameer Randolph
Racor Turbine fuel filters are the marine industry standard, but they may need to be replaced or rebuilt. The Racor 500, 900, and 1000 models are easy to rebuild, with kits available at a reasonable price. This project takes about 25-30 minutes to complete. The pressure gauges show when to change the filter, but they need to be checked when the engine is working hard. The vacuum gauge readings are also important, regardless of the hours or amount of fuel passed. The Racor filter elements are much easier to change in a seaway if necessary. It is recommended to change the filters every 200-300 hours or yearly.
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What You'll Learn
When to change your Racor fuel filter
The Racor Turbine fuel filters are the marine industry standard. While they are built to last, they will eventually need to be replaced. The Racor 500, 900 and 1000 models are easy to rebuild, with rebuild kits available at a reasonable price.
There are some generic recommendations based on engine hours, but the quality of the fuel you use can vary, even from the same fuel dock. It's important to regularly inspect your Racor fuel filter. If you have a glass bowl below the Racor, shine a flashlight behind the glass to look for sediment, debris and water in the fuel. If it looks dirty, it's time to replace the filter.
You can also buy and install a vacuum gauge on or near your filter housing, which will show and record the vacuum caused by restrictions in the filter. Once you notice a performance problem, you will know it's time to change the filters. As a rule of thumb, Racor filters can be replaced annually or every 18 months. However, some users report changing their filters every 100 hours or 500 hours.
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Replacing the gasket
The gasket is a common replacement item for Racor Turbine filters. The gasket is square in cross-section, not round, so be careful to avoid any twists as this will cause diesel leaks. The little red O-ring should be replaced each time the filter is changed.
To replace the gasket, start by removing the four machine screws that hold the bowl onto the housing. Then, slide the aluminium clamping ring up and off the bowl and remove the bowl from the housing. Once the gasket has been replaced, the turbine cover and turbine can be cleaned and re-installed. Place the slotted cover over the ball, then thread the turbine down through it and onto the filter housing. The turbine holds the slotted cover in place. Do not over-tighten—just snug is fine.
It is important to note that the check valve gasket is now properly oriented. This can be checked by referring to the exploded parts diagram that comes with the service kit. Parker Hannifin also includes a gasket sheet, which can be overlaid to ensure the correct gasket is used and to avoid confusion during installation.
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Vacuum gauge readings
Vacuum gauges are among the simplest and most valuable tools for troubleshooting fuel systems. They are typically installed at or near the primary fuel filter and are used to monitor the condition of the primary fuel filter element. As the element becomes impacted with dirt and debris, the level of effort required for the engine's fuel lift pump to pull fuel through the filter increases, resulting in a higher vacuum reading on the gauge.
The Racor Vacuum Gauge shows vacuum in "Hg (inches of Mercury) from 0 to 30. The background is white from 0 to 7, indicating the normal operating range. From 7 to 10, the background is yellow, suggesting a caution zone, and from 10 to 30, the background is red, indicating a warning zone. It is important to note that the vacuum is typically highest when the engine is operating at cruising or full rpm, so checking the vacuum while the engine is idling may not provide much information about the filter's condition.
There are a few installation options for the vacuum gauge. It can be installed in place of the filter's T access handle, which is a common practice, but this may make the filter more difficult to service and the gauge more susceptible to damage. Alternatively, the gauge can be hard-plumbed to the filter's outlet fittings, where it is safely positioned for easy reading. Another option is to remotely plumb the gauge inside or outside the engine room for more convenient reading. For vacuum gauge plumbing runs longer than 12' (3.7m), it is recommended to use hard metallic tubing instead of a hose.
Some Racor vacuum gauges have a black needle that indicates increasing vacuum. This needle can be difficult to monitor as the engine is running. To address this, Racor introduced a tell-tale needle that follows the black needle. When the engine is shut down, the black needle resets to zero, and the red tell-tale needle stays at the highest reading, allowing operators to monitor system restriction results without running the engine.
Overall, vacuum gauge readings are essential for monitoring fuel filter performance and can help prevent issues caused by clogged filters or blocked fuel lines.
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Multi-stage fuel filtration
To replace your Racor fuel filter, you will need to remove the four machine screws holding the bowl onto the housing. Once the screws have been removed, slide the aluminium clamping ring up and off the bowl, and then remove the bowl from the housing. Next, you will need to replace the gasket and clean the turbine cover and turbine. Reinstall the turbine by threading it down through the slotted cover and onto the filter housing. The turbine holds the slotted cover in place, so be sure not to over-tighten it.
It is important to note that the gasket is square in cross-section, not round, so twists are problematic and can lead to diesel leaks. Additionally, the little red O-ring should be replaced at each filter change.
Some users recommend marking the engine hours right on the filter housing to keep track of when the filter needs to be changed. Others suggest monitoring the vacuum gauge readings, regardless of hours or the amount of fuel passed. It is also recommended to visually inspect the fuel for sediment, debris, and water to determine if the filter needs to be replaced.
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Filling the filter before turning the system on
To fill the filter, take off the top of the Racor and fill it with diesel. This will introduce air into the system, so you will need to refer to your engine manual for instructions on how to prime the system. If your Racors are low enough to gravity feed, you can simply turn the racor handle to open, and the fuel will enter the Racor. Once the fuel reaches the top, turn the racor handle off and put the top back on.
If your fuel tank is positioned in a way that does not allow gravity feeding, you can use a small can, a water bottle, or a funnel with an attached tube to fill the filter. However, manually filling the filter can be challenging and increases the risk of spilling fuel.
To avoid the hassle and mess of manually refilling the filter, you can use a tool called the "Rapid Primer." This tool fits on top of the Racor and uses a small hand pump to pull fuel directly into the Racor, eliminating the need for jerry jugs or other containers. The Rapid Primer is designed to fit different-sized filters and simplifies the process of refilling the Racor fuel filter.
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