Fuel Filter Efficiency: Optimum Pressure For Racor Filters

Racor fuel filters are used to remove contamination from fuel tanks. The Racor 500 series filters, for example, are easy to maintain, clean, and use. They are also inexpensive, with some filters costing as little as $30. While there is no definitive answer to how often one should change their Racor fuel filters, some sources suggest changing them every 250 hours or annually. However, it is important to monitor the filters and change them when necessary, as dirty fuel can cause engine failure. One way to monitor the state of the filter is by installing a pressure gauge, which can be purchased from Racor or from third-party sellers.

Racor fuel filter pressure gauge faults

A faulty Racor fuel filter pressure gauge can cause a range of issues, from incorrect pressure readings to fuel leaks and even engine failure. Here are some common problems and potential solutions:

• Incorrect Pressure Readings: If your Racor fuel filter pressure gauge is giving unexpected readings, there are a few potential causes. Firstly, check the positioning of the gauge in your fuel system. If the gauge is between the fuel tank and the engine lift pump or any other pressure pump, it may be faulty. Ensure the gauge is installed between the engine lift pump and the engine high-pressure pump. Additionally, check for any blockages in the hoses and change the filters if necessary.
• Positive Pressure: If you are getting positive pressure readings, it is essential to consider the location of your fuel tank in relation to the engine and filter. If the tank is above the filter and engine, the positive pressure may be due to head pressure. Try partially squeezing the inlet line to the filter while the engine is running to see if the gauge reading changes.
• Inaccurate Readings: Pressure gauges may not always be accurate, especially at the beginning and end of their range. Minor discrepancies in readings are usually not a cause for concern.
• Leaking Fuel: In some cases, fuel may leak from the gauge installation. This can be due to an improper fit, such as when the stem is too long for the filter, preventing the lid from sealing correctly. Ensure you are using the correct gauge for your specific Racor filter model to avoid leakage.
• Air in the Gauge: Air trapped in the gauge can lead to false readings. Ensure that you remove any cellophane tape or plastic nipples covering the "ambient" pressure-sensing hole on the gauge during installation.
• Gauge Not Moving: If the gauge needle does not move at all, it may be faulty. Check if the gauge reads zero when exposed to atmospheric pressure; if not, the gauge is likely defective.
• Inconsistent Readings: If you are getting inconsistent readings from multiple gauges, it may be due to variations in gauge quality or manufacturing tolerances. Try using gauges from different manufacturers to ensure accuracy.
• High Vacuum Readings: High vacuum readings on your Racor fuel filter gauge indicate a clogged filter. Regularly monitor your vacuum readings and change the filter when the readings reach the recommended threshold.
• Incompatible Gauge: Racor has made design changes to their filters over the years, and older gauges may not fit newer filters properly. Ensure you are using a compatible gauge for your specific Racor filter model to avoid leakage and inaccurate readings.

Filter replacement frequency

The Racor representative quoted the following guidelines for changing the 220 Series Spin-on filter (fuel/water separator): 10,000 gallons, 500 hours, every other oil change, annually, or after a noticeable drop in engine power. Additionally, they stated that the filters lose their water-separating effectiveness after 1 year of inactivity or storage.

Some boat owners change their primary Racor fuel filter every 1-2 years and the secondary filter every 4 years. Others wait until they notice a drop in engine power before changing their filters.

One boat owner changes their primary filter every 1-2 years, their secondary filter every 4 years, and uses a separate electric diesel pump and 2-micron filter to cycle filter the fuel independently of the engine. They also add a diesel additive every year to kill algae.

A forum user suggests that the best practice is to change the filters every spring, but acknowledges that they have left their filters for two years while monitoring the vacuum gauge.

Another forum user says they change their filters every two years, regardless of how dirty they are, because the filter paper can be degraded by any moisture in the fuel. They have seen two filters blown out over the years, and the owners never knew until the engine stopped.

A different forum user says they have never changed a fuel filter until it was dirty, and they have never had an issue. They put clean fuel in and keep algae away, so their filter stays clean.

One boat owner says they change their primary filter every 300 hours, or every 2-3 years, and their secondary filter every 1000 hours, or every 6-7 years.

Vacuum gauge installation

A vacuum gauge is a valuable tool for monitoring the status of your fuel filter and can help prevent unexpected engine failure. It is recommended to install a vacuum gauge at or near the primary fuel filter. This will allow you to measure the vacuum between the lift pump on the engine and the filter element. As the filter element collects impurities, the gauge will begin to register a vacuum, indicating that the fuel delivery system is working harder to pull fuel through the system.

Step 1: Purchase the Necessary Parts

• Fuel filter vacuum gauge: Racor sells a vacuum gauge specifically for this purpose, or you can opt for a more affordable alternative such as the DuraChoice 2-inch oil-filled vacuum gauge from Amazon.
• 1/4" NPT tee, two 1/4" hose barbs, and two stainless steel hose clamps: These can be purchased at your local hardware store.

Step 2: Find the Best Location for the Gauge

Locate a place for the gauge that is easily accessible and avoid placing it in an area with high vibration. Make sure there is enough room to cut the hose and that any diesel that may drain out can be caught and disposed of properly.

Step 3: Prepare the Threads

Wrap the male threads on the pressure gauge and the hose barbs with Teflon tape or your preferred pipe dope. Be careful not to restrict the flow by covering the openings if using tape.

Step 4: Assemble the Fittings

Using two open-end wrenches, screw the hose barbs and gauge into the tee fitting. Be careful not to over-tighten the connections.

Step 5: Connect the Hose

Place the hose clamps on the hose, insert the barbs into the fuel line, and tighten the hose clamps.

Step 6: Test the Installation

Bleed the engine if necessary, start it up, and monitor the gauge.

Additionally, it is important to note that Racor recommends keeping the hose that runs between your remote helm gauge and the filter assembly under 14 feet in length to ensure accurate readings. For longer hose runs, use hard metallic tubing instead of hose.

Filter size and compatibility

Racor fuel filters come in a variety of sizes and types to fit different applications. When choosing a Racor fuel filter, it is important to consider the specific requirements of your engine and fuel system. The most important factors to consider are the fuel type, the flow rate, and the micron rating.

For example, the Racor 2040N-30 fuel filter element is designed for use with diesel fuel and has a micron rating of 30. It comes in a pack of 4, and the price may vary based on the size and color. Similarly, the Racor 2010TM-OR fuel filter element is designed for use with diesel fuel but has a smaller micron rating of 10. It is available in packs of 2 and 6, with the price varying based on the quantity and seller.

Another option is the Spin-On Fuel Filter/Water Separator Complete Kit 320R-RAC-01, which, as the name suggests, includes a fuel filter and a water separator. This kit is suitable for engines that require fuel filtration and water separation. The Racor 6120 series offers a range of fuel/water separator assemblies, with different models varying in features and specifications.

It is always important to refer to the specific requirements of your engine and fuel system when selecting a fuel filter. Incompatible or improperly sized fuel filters can lead to reduced engine performance and potential damage.

Fuel tank and engine placement

The placement of the fuel tank and engine is an important consideration when changing Racor fuel filters. The Racor fuel filter should be placed between the fuel tank and the engine lift pump or any other pressure pump to ensure the accuracy of the gauge. If the filter is placed between the pressure pump and the engine high-pressure pump, it may lead to "pumping" fuel through the filter membrane, which can rupture the membrane and send dirty fuel to the high-pressure pump.

It is also important to consider the height of the fuel tank in relation to the engine and filter. If the tank is higher than the engine or filter, it can affect the pressure reading, as each foot of head can result in approximately 0.4 PSI of pressure. Therefore, it is recommended to check for head pressure, especially if there is a significant height difference.

Additionally, the accessibility of the fuel tank and engine can impact the ease of changing Racor fuel filters. In some cases, it may be necessary to install a vacuum gauge or a fuel polisher to monitor and maintain the fuel system.

When changing Racor fuel filters, it is crucial to refer to the engine manufacturer's recommendations and specifications. Different engines may have specific requirements for filter placement and maintenance. It is also important to consider the fuel type and quality, as common-rail diesel engines, for example, have higher pressure requirements and are more susceptible to poor fuel quality.

To ensure the proper functioning of the fuel system, it is essential to follow the manufacturer's guidelines for filter placement, maintenance intervals, and fuel quality. By considering the height, placement, and accessibility of the fuel tank and engine, as well as utilizing appropriate monitoring tools, one can effectively maintain Racor fuel filters and help prevent engine breakdowns due to fuel-related issues.

Frequently asked questions