Parker Racor 400 Series User manual

400 Series
Spin-on Fuel Filter/Water Separators
Contact Information:
Parker Hannin Corporation
Racor Division
P.O. Box 3208
3400 Finch Road
Modesto, CA 95353
phone [phone]
209 521 7860
fax [phone]
[e-mail]
www.parker.com/racor
Overview
400 Series Spin-on Fuel Filter/Water
Separators are designed to handle
today’s tough gasoline and diesel
filtration problems and may be used on
the vacuum or pressure side of the fuel
transfer pump.
Filtration needs should be based on
application, fuel quality, operating
climates, and maintenance schedules.
If you have questions about this
product, contact our Technical Support
Department, 8 AM to 5 PM, Pacific
Standard Time, Monday through Friday,
at [phone] ext. 7555.
Instruction Part Number 22209 Rev F
Product Features:
• Hand (palm) operated fuel
priming pump
• Proprietary, high-capacity,
water-repelling Aquabloc®II
filters available in 2, 10, and
30 micron.
• Reusable contaminant
collection bowls with self-
venting drain.
• 4-port die-cast aluminum head
(two inlets, two outlets) and a
unitized mounting bracket for
installation convenience.
• Optional 12 or 24 volt DC, 200
watt, in-bowl fuel heater, water
detection kit, and vacuum gauge
available. Danger! Optional
parts are not for use with gasoline
applications.

Mounting
TOP VIEW
Installation Diagram
Valve 1 Valve 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
lift should not exceed 4 inHg.
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
main 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 service clearance below filter
assembly of at least 2 in. (5.1 cm)
Valve 3
Optional Bypass Installation and Operation
(allows user to service filter without shutting down engine.)
Valves 1 2 3
Unit On-line Open Open Closed
Unit Off-line Closed Closed Open
Suction (vacuum) Side:
Primary (first) filter - use 30 micron.
If it is the only filter in the system,
use 2 or 10 micron.
3/8 in. (8 mm) diameter clearance for fasteners.
2.25 in.
(5.7 cm)
445R:
8.5 in. (21.6 cm)
460R:
10.2 in. (25.9 cm)
490R:
11.0 in. (27.9 cm)
4120R:
14.2 in. (36.1 cm)
Vent Plug
Hand actuated
primer pump
OUT OUT
IN IN

Refer to Mounting Instructions
and Installation Diagram and
install as follows:
Make sure engine is off and1.
cool to touch.
445R, 460R and 490R: Apply2.
thread sealant to NPT fittings
(do not use thread tapes
as particles may break off
and contribute to clogging
element). 4120R: Apply motor
oil or diesel fuel to O-ring on
UNF fittings.
Thread fittings into3.
appropriate fuel ports and
tighten snugly. Plug unused
ports (if any) with port plugs
and tighten snugly.
Mount filter vertically in a4.
protected area and away from
heat sources. Maintain at least
2.0” (5.1 cm) of clearance
below filter for draining water
and servicing element.
Attach fuel lines to filter.5.
Avoid tight bends and rubbing
areas when routing hose.
Connect water probe and6.
heater wires (if equipped).
Open vent plug and operate7.
hand primer pump until fuel
purges from vent.
Close vent plug and start8.
engine. Correct as necessary
with engine off.
Installation
Guidelines
Service
Element replacement frequency
is determined by contamination
level in fuels. Fuel flow to
engine becomes restricted as
element gradually plugs with
contaminants, resulting in
noticeable power loss and/or
hard starting. As a guideline,
change element every 500
hours, 10,000 miles, every
other oil change, annually,
or at first indication of power
loss, whichever occurs first.
Always carry extra replacement
elements as one tankful of
excessively dirty fuel can quickly
plug a filter.
Make sure engine is off and
1.
cool to touch.
Close all fuel valves, if2.
applicable, to make sure
excess fuel does dot spill
during servicing.
Disconnect water probe3.
and heater connectors,
if equipped.
Open vent plug on4.
mounting head.
Drain unit of fuel.5.
Remove bowl and element.6.
Dispose of element properly.
Bowl is reusable.
Lubricate new element7.
seals with motor oil or clean
fuel and install only with
new element.
Re-install bowl and tighten by8.
hand only - do not use tools.
Connect water probe9.
and heater connectors,
if equipped.
Open all fuel valves,10.
if applicable.
Operate hand primer pump11.
until fuel purges from vent.
Close vent plug and start12.
engine. Correct as necessary
with engine off.
Draining the
Collection Bowl
Water is heavier than fuel and
will settle to bottom of bowl
and appear different in color if
collected in a clear jar. In high
humidity environments, check
bowl frequently (daily if a poor
fuel source is suspected). 400
Series bowls are equipped with a
water sensor port that will accept
a water probe (sold separately)
and will alert operator of a high
water condition in the filter.
Do NOT use water probe
electronics in gasoline
applications - an explosion
could occur.
Make sure engine is off and1.
cool to touch.
Open vent plug.2.
Drain water from filter by3.
opening self-venting drain.
Close as soon as all water
has evacuated.
If drain is open too long, the
entire filter may drain completely
of water and fuel.
Follow priming instructions.4.
Priming
Prime filter by operating hand1.
primer pump until fuel spills
out of vent port.
Close vent plug snugly.2.
Verify all other connections3.
are tight.
Start engine and check for4.
leaks. Correct as necessary
with engine off.
Trouble Shooting
If filter fails to hold prime, first
check vent plug, drain valve,
fittings, head, element, and bowl
are properly tightened. Next,
check fuel line connections and
verify they are free of pinches or
unnecessary bends and check to
see if fuel tank strainer (or pick-
up tube) is clogged. If problems
persist and element is new,
call Racor Technical Support
at 800-344-3286, 8 AM to 5 PM,
Pacific Standard Time.

Performance Information
Test results are from controlled laboratory testing. Field results may vary.
*PSI x 2.036 = inHg. (PSI x 6.895 = kPa)
SAE J1839 Water Separation
50 100 150
100
98
96
94
92
90 0
Time (minutes)
%
Efficient
4120490460445
8
6
4
2
0
PSI*
600500400300200100
Grams
SAE J905 Solids Capacity
SAE J905 Fuel Flow Restriction
1.0
0.6
0.4
0.2
1209060300
0.0
4120490460445
PSI*
Flow (GPH)
0.8
Installing Optional Features
Optional In-Bowl
Heater:
The in-bowl heater is a cold
weather starting aid with an
internal automatic thermostat
that turns the heater on if
fuel temperature drops below
45°F (7°C). Heat is supplied
just below the filter to melt
wax crystals and allow fuel to
efficiently pass through. The
heater will automatically turn
off at about 75°F (24°C). The
200 watt heater is available in 12
or 24 vdc (volts, direct current).
The heater is operated by turning
on the ignition switch for a
minimum of 5 minutes prior to
starting the engine.
Customer
Supplied Items:
Because of the heater power1.
demand, 20 amps for the 12
vdc and 10 amps for the 24
vdc, an additional relay is
recommended for the safest
method of installation. Racor
offers two relay kits, available
from your dealer, RK 11861
for the 12 vdc systems or RK
11862 for the 24 vdc systems.
These kits include an in-line
fuse holder (and fuse) and the
RK 11862 kit also includes a
resistor. Use the 25 amp fuse
with the 12 vdc and the 15
amp fuse (and resistor) with
the 24 vdc systems. See page
11 for more details.
An on-off toggle switch may
2.
be used to control power
to heater relay. This allows
the operator to cut power to
heater relay during summer.
All wires should be 14 AWG
3.
(American Wire Gauge),
minimum.
Installation:
Either heater wire may be1.
used for Hot (+) or Ground
(-).
Wire/terminal connections2.
should be soldered and
crimped.
Run wires in protected3.
locations. Avoid hot surfaces
and places that could pinch
or rub on the wires.
* Use the 15 amp fuse and resistor with 24 vdc systems.
Battery
- + Ignition
Switch
*fuse*resistor
Relay
C4 B2
A5 E3
Connector
Fuse Box
1 amp fuse
Manual on-off
switch (optional)

445R 460R 490R 4120R
Max. Flow Rate 45 GPH (170 LPH) 60 GPH (227 LPH) 90 GPH (341 LPH) 120 GPH (454 LPH)
Fuel Port Size 3/8”-18 NPTF
(SAE J476)
3/8”-18 NPTF
(SAE J476)
3/8”-18 NPTF
(SAE J476)
3/4”-16 SAE
(SAE J1926)
Total Number of Ports:
(total inlets)
(total outlets)
4
2
2
4
2
2
4
2
2
4
2
2
Min. Service Clearance 2.0 in. (5.1 cm) 2.0 in. (5.1 cm) 2.0 in. (5.1 cm) 2.0 in. (5.1 cm)
Center Threads 1”-14 1”-14 1”-14 1”-14
Height 9.3 in. (23.6 cm) 11.0 in. (27.9 cm) 11.8 in. (30.0 cm) 15.0 in. (38.1 cm)
Width 4.5 in. (11.4 cm) 4.5 in. (11.4 cm) 4.5 in. (11.4 cm) 4.5 in. (11.4 cm)
Depth 4.8 in. (12.1 cm) 4.8 in. (12.1 cm) 4.8 in. (12.1 cm) 4.8 in. (12.1 cm)
Weight (dry) 2.5 lb (1.1 kg) 2.7 lb (1.2 kg) 2.9 lb (1.3 kg) 3.9 lb (1.8 kg)
Clean Pressure Drop 0.17 PSI (0.01 bar) 0.39 PSI (0.03 bar) 0.95 PSI (0.07 bar) 0.85 PSI (0.06 bar)
Max. Pressure130 PSI (2.07 bar) 30 PSI (2.07 bar) 30 PSI (2.07 bar) 15 PSI (1.03 bar)
Available Options:2
(water sensor)
(heater)3
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Bowl Capacity
(water)
(with heater)
4.0 oz. (118 ml)
3.5 oz. (104 ml)
4.0 oz. (118 ml)
3.5 oz. (104 ml)
4.0 oz. (118 ml)
3.5 oz. (104 ml)
2.8 oz. (82 ml)
2.4 oz. (70 ml)
Water Removal Efficiency 99%
Ambient Temp. Range -40° to +255°F (-40° to +121°C)
Max. Fuel Temp. 190°F (32°C)
Specifications
1Pressure installations are applicable up to maximum PSI shown. Vacuum installations are recommended.
2Do not use with gasoline applications.
3Maximum power requirements for in-bowl heater option: 12 vdc (200 watt) = 16.6 amps,
24 vdc (200 watt) = 8.3 amps. See section on heater relay kits, if needed.

Part No. Description
RK 101101. Metal Vent Plug Kit (3/8”-24 SAE)
RK 224252. Mounting Head Kit (3/8”-18 NPTF Ports)
(includes head, #1, #3 and #4)
RK22168-05BP Mounting Head Kit (16 mm X 1.5 Ports)
(includes head, #1, #3 and #4)
RK 227983. Bypass Valve
RK 205054. Element Gasket Kit
5. See Replacement Element Chart
RK 223336. Bowl Gasket Kit
7. Replacement Bowl Kits (includes bowl, #6, #8, and #9)
RK 21113-13-11 Clear Bowl Kit
RK 22616-01** Heated Bowl Kit
(Clear bowl with 12 vdc heater)
RK 22616-02** Heated Bowl Kit
(Clear bowl with 24 vdc heater)
RK 201268. Plug Kit (1/2”-20 SAE)
RK 304769. Self-Venting Drain Kit
Additional Parts (not shown)
RK 22323** Heater Connector Kit
** In-bowl heater may require a Heater Relay Kit.
Maximum power requirements:
12 vdc = 16.6 amps, 24 vdc = 8.3 amps.
445R, 460R, and 490R
Replacement Parts 1
5
3
6
9
2
4
7
8

Part No. Description
RK 101101. Metal Vent Plug Kit (3/8”-24 SAE)
RK 221682. Mounting Head Kit (3/4”-16 SAE Ports)
(includes head, #1, #3 and #4)
RK 227983. By-Pass Valve Kit
RK 205054. Element Gasket (includes #4 and #6)
5. Replacement Elements
R120S 2 micron
R120T 10 micron
R120P 30 micron
RK 223336. Bowl O-ring
7. Replacement Bowl Kits (includes bowl #6, #8 and #9)
RK 30063 Clear Bowl Kit
RK 30900** Heated Bowl Kit
(Clear bowl with 12 vdc heater)
RK 30925** Heated Bowl Kit
(Clear bowl with 24 vdc heater)
RK 201268. Plug Kit (1/2” SAE)
RK 304769. Self-Venting Drain Kit
** In-bowl heater may require a Heater Relay Kit.
Maximum power requirements:
12 vdc = 16.6 amps, 24 vdc = 8.3 amps.
1
5
4
8
6
9
2
3
7
4120R
Replacement Parts

Model Number 2 micron
(Final Filtration)
10 micron
(Secondary
Filtration)
30 micron
(Primary Filtration)
445R R45S or R47S R45T R45P
460R R60S R60T R60P
490R R90S R90T R90P
4120R R120S R120T R120P
Replacement Elements
Optional Dual Layer Media Filter
Dual-layer media oers enhanced
dirt-holding capacity, extended
lter life, and ensures a more
complete removal of all size
contaminants. e R47S lter
replaces the R45S and provides
removal eciencies of 99.98%
(nominal) on 2 micron particles,
still much greater than the 50-90%
eciency of most single-stage
lters.
R47S
Inner Media
Outer Media
Vacuum Gauges
Vacuum gauges are available to
monitor element condition and as
the lter element slowly becomes
clogged with contaminates the
restriction (resistance to ow)
increases. e fuel pump still tries
to draw fuel (suction) but because
of restriction, less fuel is delivered
to engine and instead more air is
pulled from it (fuel de-gassing).
Results can cause engine to lose
power and eventually stall.
By installing a vacuum gauge in
the fuel system on the outlet side
of the lter, visual monitoring of
element condition is possible.
Specifications RK 11233 1606B
Description
Silicone dampened,
0-30 inHg.
Instrument panel installation.
Includes gauge and
two ttings.
Instrument panel installation.
Threads 1/4” NPT back
bracket mount.
1/4” NPT back
bracket mount.
Dimensions 2.0” W x 1.9” D 2.0” W x 1.9” D
Dial 2 in. 2 in.
Weight 0.4 lb (0.2 kg) 0.4 lb (0.2 kg)
Special Notes: For severe vibration applications, mount gauge on stable, remote
location and connect using exible tubing. Additional gauges available - contact your
local distibutor.

Description Hose (H)/
Thread (T) T1 Part No.
For 445R, 460R,
and 490R models
3/8”
1/2”
3/8” NPT
3/8” NPT
951-N6-H6
951-N6-H8
For 4120R
model
3/4”-16 SAE 3/4” SAE 911-O8-J8
3/4”-16 SAE
7/8”-14 SAE
3/4” SAE
3/4” SAE
913-O8-J8
913-O8-J10
3/8”-18 NPT
1/2”-14 NPT
3/4” SAE
3/4” SAE
911-O8-F6
911-O8-F8
Hose Barb
H
T1
TT1
SAE 37* Elbow
T
T1
NPT Female
T
T1
Note: The T1 side of the tting threads into the mounting head ports.
Fittings
Specifications RK 21069 RK 30964 RK 30880
Threads 1/2”-20 Threads 1/2”-20 Threads 1/2”-20 Threads
Description
One piece design with
two wires. Requires a
detection module.
Includes detachable
2-wire connector.
Requires a
detection module.
Includes detachable
3-wire connector, built-
in detection electronics
and under-dash warning
light. Probe sends
ground signal to light.
Voltage 12 or 24 vdc 12 or 24 vdc 12 or 24 vdc
Power Draw:
(12 volt)
(24 volt)
N/A N/A 5 Milliamps
10 Milliamps
Maximum Load N/A N/A 1 Amp
Weight 0.03 lb (0.01 kg) 0.02 lb (0.01 kg) 0.4 lb (0.2 kg)
Caution: Never wire a water probe directly to voltage or another brand of detection module.
Water Probe Kits
Racor oers a wide selection of
water probes, each designed for
use with particular models and
installation requirements. ese
probes are available in various
congurations to t every Racor
lter/separator. e water probe
is only a component in the water
detection system and will not
work without a Racor electronic
detection module.
RK 30880 has an electronic
detection module built-in to
its design and has the simplest
installation procedure. Wiring
instructions are supplied with
each water detection module.

Water Detection Modules
Racor Water Detection Kits
are available for under dash,
in-dash, and remote mount
installation. These units may be
used with any Racor fuel filter/
water separator and water probe.
An electric detection module
analyzes electrical resistance at
the water probe and determines
if water is present. Units reset
automatically after removing
water (unless specified). All
water detection module kits
include an RK21069 water probe.
Under Dash Modules
Specifications RK 12870 RK 12871
Voltage 12 vdc 24 vdc
Features Light and Buzzer
Same as RK12870
Description
Lamp illuminates and buzzer sounds when
water is detected. Water must be drained to
reset light and stop buzzer.
Dimensions 1.4” H x 1.25” D x 1.4” W
Power Draw 1 Milliamp
Maximum Internal Load 30 Milliamps
Weight 0.2 lb (0.1 kg)
Part Number
RK 12870 or
RK 12871
In-Dash Modules
Specifications RK 20726
Voltage 12 or 24 vdc
Features Light and Buzzer
Description
Red DRAIN lamp illuminates continuously and buzzer sounds momentarily
when water is detected. Power-up self diagnosis feature and
circuit protection included.
Dimensions12.2” Diameter x 3.2” Depth
Power Draw:
(12 volt)
(24 volt)
3 Milliamps
13 Milliamps
Maximum Internal Load 30 Milliamps
Weight 0.4 lb (0.2 kg)
1Cut 2.0” diameter hole to mount gauges in instrument panel.
Part Number
RK 20726
Remote Mount Modules
Specifications RK 14329 RK 14321
Voltage 12 vdc 24 vdc
Features Sends Hot (+) Signal Sends Hot (+) Signal
Description
Receives signal from water probe or vacuum switch
(not included) then sends a signal to horn or lamp.
Must use with relay if power draw is over 1 amp.
Same as RK14329
but sends
24 vdc hot (+) signal.
Dimensions10.7” H x 2.5” D x 2.8” W 1.0” H x 1.5” D x 2.0 W
Power Draw: 14 Milliamps 10 Milliamps
Maximum Internal Load 30 Milliamps 30 Milliamps
Weight 0.3 lb (0.1 kg) 0.4 lb (0.2 kg)
Part Number
RK 14329
Part Number
RK 14321
Note: Additional modules available - contact your Racor distributor.
Note: Additional modules available - contact your Racor distributor.
Note: Additional modules available - contact your Racor distributor.

Electrical Heater Relay Kits
The following relay kits may
be necessary when installing
Racor Heater Kits due to power
demand. Standard OE fuses,
Specifications RK 11861 RK 11862 RK 19490-12 RK 19490-24
Description
Heater Relay Kit,
Includes fuse
and holder.
Heater Relay Kit,
Includes fuse
and holder.
Heavy-Duty
Relay Kit
Heavy-Duty
Relay Kit
Voltage 12 vdc 24 vdc 12 vdc 24 vdc
Detection Module Remote Mount Remote Mount Under Dash Under Dash
Maximum Watts 300 360 600 900
Maximum Amps 25 15 50 37
Dimensions 1.3” H x 1.6” D x
1.1” W
1.3” H x 1.6” D x
1.1” W
1.7” H x 2.9” D x
5.1” W
1.7” H x 2.9” D x
5.1” W
Weight 0.3 lb
(0.1 kg)
0.3 lb
(0.1 kg)
1.6 lb
(0.7 kg)
1.6 lb
(0.7 kg)
Caution: If you are uncertain if your electrical system can provide the additional power draw, consult your
equipment distributor or qualied electrician.
H
DW
H
DW
wiring and alternators may be
unable to carry the load without
overheating or shorting, creating
a serious condition. Wire/
terminal connections should be
soldered and crimped.

May 2008© 2008 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