Parker Racor RK15438-01 User manual

100 Watt Heater Kits
RK15438-01 (12 VDC) and RK15438-02 (24 VDC)
For 500FG Turbine Filters
Contact Information
Parker Hannifin Corporation
Racor Division
P.O. Box 3208
3400 Finch Road
Modesto, CA 95353
phone [phone]
209 521 7860
fax [phone]
[e-mail]
parker.com/racor
Please read and understand all
instructions prior to installation.
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 filter assembly
just below the replacement filter
to melt wax crystals and allow
fuel to pass through the filter for
quick, easy starting. The 100 watt
heater is operated by turning the
ignition switch ON for a minimum
of five minutes prior to starting the
engine.
Note: Racor electrical options
are for use with diesel
applications only.
As of August 2013, all 500FG
Turbine Series heaters are
equipped with a thermal
cut-off (TCO) fuse. This is a
running change.
Thermal cut-offs provide protection
against overheating conditions,
which could lead to fuel filter
component damage.
Additionally, a green heat insulator
pad has been secured to the
heater disc top surface to provide
additional protection and heat
transfer to the filter. Caution!
Do not attempt to remove the
insulator as it is riveted to the
heater disc. Note—some color
transfer to the bottom filter cap is
normal.
Instruction Part Number 11-2022 Rev A

Supplies
The following customer supplied items
are recommended for best results
when installing a heater:
• Heater power demand is 8.3 amps
for 12 vdc and 4.2 amps for 24
vdc. Due to power demand, we
recommend our relay kit for the
safest method of installation. We
offer several relay kits available
from your Racor distributor.
• Refer to the Heater Relay Kit
Selection Guide
• A ON-OFF toggle switch (customer
supplied) may be used to control
power to heater relay. This allows
the operator to cut power to the
heater relay during summer use or
servicing procedures.
• All wires should be 14 AWG
(American Wire Gauge) minimum.
• Threadlocker such as Loctite #242.
• Motor oil, shop towels, clean fuel
and torque wrenches.
Installation
This procedure may be done with
the unit on the vehicle (if space
permits) or on a work bench. When
performing procedure on vehicle,
remove ground cable from battery as
a safety measure before starting.
Note: Use a toothpick to remove
old gaskets that are stuck in the
sealing gland so the surfaces are not
scratched. Clean all sealing surfaces
with a clean, dry cloth.
Refer to Exploded View on page
4 as you read these instructions
and install the heater.
1. Drain all fuel from the Racor by
opening drain valve (item# 17).
2. Remove T-handle (item# 1) and lid
(item# 3), discarding old T-handle
O-ring (item# 2) and lid gasket
(item# 4).
3. Remove filter element (item# 5)
from base/housing (item# 8).
4. Remove the four (4) bowl ring
capscrews (item# 19) and pull the
bowl (item# 15) from the base/
housing (item# 8). You may need
to tap the side of the bowl (item#
15) with a rubber mallet to free it. Remove the rubber bowl gasket (item#
14) and discard. Clean the base (item# 8) gasket gland of any debris with a
soft shop cloth.
5. Grasp the turbine centrifuge (item# 13) with a gloved hand and unthread it
counter-clockwise to remove it. The conical baffle (item# 12) will also come
off with the centrifuge. An aluminum checkball (item# 11) should be inside
it along with a light red colored checkball seal (item# 10).
6. Notice how the checkball seal (item# 10) is positioned within the base
(item# 8)—the radiused side faces toward the checkball—see image below.
Install your new check ball seal at this time in the same orientation so it is
not forgotten in the re-assembly process. Set these parts to the side, you
will use them later.
7. Apply a light coating of motor oil on the o-ring of the 2-wire feed-thru
(item# 9) and insert connector end thru the base port (next to the fuel inlet
port). Tighten the feed-thru housing into the base port. Tighten the 5/8”
feed-thru housing hex (specification: 90 inch pounds). The o-ring will seal
with just light hand tightening.
8. Carefully lower the heater (item# 6) into the filter housing –thermostat end
first - over the center tube and pull the wires through the correct opening
at bottom of base (item# 8). See image below.
Conical Baffle
Checkball
500FG Partial
Cutaway
Base
Seal

9. Position, then push the heater bracket tabs onto filter base runner as shown
in the illustration below.
10. Attach the flag connectors of the heater to the 2-wire feed-thru. The wires
are color-coded; however, the heater has no polarity so you can hook either
wire to either of the two wires from the feed-thru plug. Use pliers to ensure
the connectors seat properly
11. The wires must be routed smoothly so they go around the distance from the
feed-thru to the heater. In the next step, the centrifuge and conical parts will
be re-attached to the base. The wires should be clear of the conical (item#
12) and be ‘hidden’ within the void of the conical. Also, the wires should not
be pinched by the installed conical if installed properly.
12. Now re-install the turbine centrifuge, checkball, checkball gasket, and
conical parts (from step 5) onto the filter base. Start the threading process
slowly so you don’t cross-thread the centrifuge threads. Once started, hand
tighten snugly (specification: 90 inch lbs). Double-check to make sure the
heater wires are not protruding or getting pinched by the conical.
13. Apply a generous coating of
silicone grease to the new bowl
gasket and position it in the base
gasket gland. The grease should
hold the gasket in position.
Note: If the gasket appears to
be a smaller diameter than the
base gasket gland, it may be
necessary to ‘stretch’ it by pulling
on opposite ends a few times.
Do this a little at a time until the
gasket lays flat within the gland.
14. Secure the bowl to the base
using the bowl ring and four
capscrews. Note: Using a shop
cloth, clean the capscrew threads
of any moisture or debris. Apply
a drop or two of threadlocker to
threads. Avoid cross-threading
the base threads by starting each
capscrew one at a time. Start the
thread engagement by hand. Do
not force the capscrew, it should
thread several turns by hand
with little resistance. Tighten
each capscrew in a ‘cross-wise’
pattern hand tight (specification:
55-65 in.lbs) Do not over tighten
to avoid stripping out the base
threads! Ensure the bowl drain is
closed.
15. Replace the filter element into
the housing and prime the Racor
by filling the housing slowly with
clean fuel.
16. Apply silicone grease to the new
lid gasket (same size as the bowl
gasket) and T-handle O-ring.
Re-attach the lid and T-handle to
the housing and tighten snugly
by hand only. Do not use tools for
leverage. (specification: 90 in.lbs)
17. Prime the fuel system per
manufacturer’s instructions, if
applicable.
18. Reattach the battery. Start the
engine and let it run for a minute.
Check the fuel system for leaks.
Correct as necessary with the
engine off and pressure relieved
from the filter assembly.
500FG Partial Cutaway
Thermostat
Heater with
insulator—do not
remove insulator
from heater.
Bracket Tab
Center
Tube

1. T-handle
2. T-handle O-ring
Exploded View
For questions or assistance, please call
Racor Technical Support at [phone]
or [phone] ext 7555.
3. Lid
4. Lid Gasket
5. Filter
6. Heater
7. Bracket
8. Base/Housing 9. Heater Feed-thru
10. Checkball Gasket
11. Checkball
12. Conical Baffle
13. Turbine Centrifuge
14. Bowl Gasket
15. Bowl
16. Water Probe Port Plug
17. Bowl Drain
18. Bowl Ring
19. Capscrews

HEATER WIRING
INSTALLATION
Caution! Please read carefully
before beginning installation.
1. Never power up the heater if
there is no fuel in the Racor
filter, severe damage may
result to the heater and filter
assembly.
2. During equipment or vehicle
servicing, always ensure
power to the Racor heater is
turned off. We recommend
the installation of a customer-
supplied power control switch
(see electrical schematic).
3. Check contaminant collection
bowl daily for accumulated
water. Water is heavier than
diesel fuel and will fall to the
bottom of the bowl. Drain
water before the level reaches
the bottom of the turbine
centrifuge. Do not allow water
to rise to the level of the
heater.
4. Ensure wiring installation
diagram is closely followed
and the proper safety fuse
is used. If a fuse should fail,
determine the cause and
correct it before installing a
new fuse and using the heater
again.
5. Exterior wiring connections
should be soldered, crimped
and sealed for protection
against shorting.
6. Route wires in protected
locations, away from hot
or moving surfaces and
places that could expose
them to chemical contact or
environmental debris.
7. Inspect all wiring and
connections for unsafe
conditions annually or every
12,000 miles, whichever
occurs first.
8. Study the wiring illustration of
your system before starting.
Due to the power consumption
of the heater (12 vdc = 8.3
amps, 24 vdc = 4.2 amps)
an external relay is required.
Racor offers relay kits for this
application; refer to the Heater
Relay Kit Selection Guide,
below. Racor Relay kits include
instructions on how to attach
them to the Racor heater.
RK 11861 or RK 11862
Relay Kits
Heater Kits
Recommended Racor Heater Relay Kit
Heater In Use Use Kit Number
RK15438-01
12 VDC
100 Watts
8.3 Amps
Single (1) RK 11861
Dual (2) RK 11861
RK15438-02
24 VDC
100 Watts
4.2 Amps
Single (1) RK 11862
Dual (2) RK 11862
Racor Heater Relay Kit Information
Note - Racor heater relay kits are ordered separately.

Schematic - For Light-Duty Power Relay Kits: RK 11861 and RK 11862
Battery
+ -
Fuse**
Ignition
Switch
Relay
Optional
Toggle
Switch
Racor
Fuel
Heater
Racor 2-wire Heater
Connection Diagram
Racor ‘2-wire’ fuel heaters
have no polarity!
Either wire may be used for hot (+)
or ground (-).
30
86
87
85
Black 14
Red 18 White 18
Green 14
+
+ +
_
Fuse Box
1A Min.
**Fuse selection: Use 10 amp fuse for 12 VDC heater and 6 amp fuse for 24 VDC heater.

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May 2013© 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