How the Three-Stage Filtration Process Works
The Racor 500FG2 removes fuel contaminants through a three-stage process that addresses everything from large debris to microscopic water droplets. Understanding how each stage works helps explain why this unit is so effective at protecting engine components.
In Stage 1 - Separation, fuel flow drives a stationary turbine that uses enhanced centrifugal force to fling large solids and free water outward and downward, away from the fuel stream. Stage 2 - Coalescing follows, where smaller water droplets and fine solids collect on a conical baffle and fall into the collection bowl below. Finally, Stage 3 - Filtration passes the fuel through the Aquabloc water-repelling filter element, which captures remaining particulates and achieves near-complete water separation before fuel reaches the engine.
Engine Protection Against Common Fuel Contaminants
Modern fuels, particularly low distillate blends, are prone to carrying a range of contaminants that can cause serious damage to injectors, fuel pumps, and other precision engine components. The 500FG2 is built to intercept all of these before they reach your engine.
The unit protects against dirt and rust particles that cause abrasive wear, algae growth that clogs fuel lines and injectors, asphaltites and varnishes that foul injector tips and reduce spray quality, and water that leads to corrosion, microbial growth, and injector damage. With a water removal efficiency of 99% and a 2 micron filtration rating on the included element, the 500FG2 provides a high level of protection for both gasoline and diesel engines.
Installation and Positioning Guidelines
For best performance, the 500FG2 should be installed on the vacuum (suction) side of the fuel transfer pump, between the fuel tank and the pump inlet. This positioning maximises water separation efficiency because the pump does not emulsify water before it reaches the filter.
The unit must be installed within 10 degrees of vertical. When the fuel tank is positioned higher than the filter, a shut-off valve must be installed between the tank and the filter inlet to allow safe servicing. When the tank is lower than the filter, a check valve with light or no restriction should be used to maintain prime. Fuel tank lift on the suction side should not exceed 5 feet (1.5 m) or 4 inches of mercury (inHg) of inlet piping restriction.
Maintain a service clearance of at least 5.0 in. (12.7 cm) above and 2.0 in. (5.1 cm) below the filter assembly to allow for element changes and bowl draining. Keep fuel line restrictions to a minimum by using the largest practical fuel hose and avoiding sharp bends or kinks.
- Install on the vacuum side of the fuel transfer pump for optimum water separation
- Mount within 10 degrees of vertical
- Install a shut-off valve between tank and filter inlet when tank is higher than filter
- Install a check valve when tank is lower than filter to maintain prime
- Do not exceed 5 ft (1.5 m) of lift or 4 inHg of inlet restriction on suction-side installations
- Allow 5.0 in. (12.7 cm) above and 2.0 in. (5.1 cm) below for servicing clearance
Filter Element Replacement and Servicing
The T-handle lid design makes element changes straightforward without the need for tools. To service the unit, remove the T-handle and lid, extract the used filter element using the bail handles with a slow upward twisting motion, and dispose of it according to local regulations. Replace the lid gasket and T-handle O-ring with each filter change, lubricating the new seals with clean fuel or motor oil before installation.
Replacement frequency depends on fuel contamination levels. As a general guideline, replace the element every 500 hours, every other oil change, when a vacuum gauge (optional) reads between 7 and 10 inHg, when power loss is noticed, or annually - whichever comes first. Always carry a spare element, as a single tankful of heavily contaminated fuel can plug a filter rapidly.
Replacement filter elements are available in 2 micron (2010SM-OR), 10 micron (2010TM-OR), and 30 micron (2010PM-OR) ratings. Use only genuine Racor Aquabloc replacement filters to maintain filtration performance.
Draining the Collection Bowl
The plastic bowl collects separated water and contaminants during operation. Inspect and drain the bowl daily or as conditions require. The bowl must be drained before accumulated water reaches the top of the turbine centrifuge.
For vacuum-side installations, close the inlet valve before opening the drain at the bottom of the bowl into a suitable container. Close the drain promptly after evacuation to avoid draining fuel from the entire assembly. For pressure-side installations, head pressure will push water and contaminants out of the drain while keeping the filter primed - again, close the drain promptly after the water has been evacuated.
Optional Accessories and Upgrades
The 500FG2 is compatible with a range of optional accessories that expand its functionality. An optional T-handle vacuum gauge (part RK 11-1969) monitors filter condition by measuring restriction - as the element loads with contaminants, restriction increases and the gauge signals when it is time for a change.
An optional in-filter heater kit is available in 12 VDC (RK 15438-01) and 24 VDC (RK 15438-02) versions. The heater includes an internal automatic thermostat that activates when fuel temperature drops below 50 degrees F (10 degrees C) and shuts off at 80 degrees F (27 degrees C), helping to melt wax crystals in cold weather for easier starting. An optional bypass valve arrangement also allows the filter to be serviced without shutting down the engine.
Port Connections and Thread Compatibility
The 500FG2 uses 3/4"-16 UNF ports conforming to the SAE J1926 straight thread with O-ring seal standard. This design compresses an O-ring between the angular sealing surface of the female port and the shoulder of the male fitting end, providing a reliable, leak-resistant fuel connection. Thread sealant paste (not tape) is recommended where applicable.
Racor also offers alternative port configurations for metric and European applications. Refer to the Racor Port Thread Information document available on the product page for full thread specifications and fitting torque values.
Specifications
- Model: 500FG2
- Maximum Flow Rate: 60 GPH (227 LPH)
- Included Filter Element: 2010SM-OR (2 micron)
- Available Replacement Element Ratings: 2 micron (2010SM-OR), 10 micron (2010TM-OR), 30 micron (2010PM-OR)
- Bowl/Shield: Plastic Bowl
- Port Size: 3/4"-16 UNF (SAE J1926)
- Gauge and Valve Included: No
- Water Removal Efficiency: 99%
- Water in Bowl Capacity: 3.7 oz. (109 ml)
- Maximum Working Pressure: 25 PSI (1.7 bar)
- Clean Pressure Drop: 0.25 PSI (1.7 kPa)
- Height: 11.5 in. (29.2 cm)
- Width: 5.8 in. (14.7 cm)
- Depth: 4.8 in. (12.2 cm)
- Weight (dry): 4.0 lb (1.8 kg)
- Ambient Temperature Range: -40 to +255 degrees F (-40 to +121 degrees C) when fuel temp is 80 to 190 degrees F (27 to 88 degrees C)
- Service Clearance Above Assembly: 5.0 in. (12.7 cm)
- Service Clearance Below Assembly: 2.0 in. (5.1 cm)
- Housing Construction: Die-cast aluminium
- Maximum Vacuum-Side Lift: 5 ft (1.5 m) or 4 inHg inlet restriction
- Installation Orientation: Within 10 degrees of vertical
Key Features
- Three-stage separation, coalescing, and filtration process: removes virtually all water and contaminants before fuel reaches the engine
- 99% water removal efficiency: protects injectors, fuel pumps, and precision engine components from water-related damage
- 2 micron Aquabloc filter element included: captures fine particulates and repels water at the filtration stage
- 60 GPH maximum flow rate: suitable for a wide range of marine gasoline and diesel engine applications
- Plastic bowl for visual inspection: allows quick checks of accumulated water and contaminants without disassembly
- T-handle lid design: enables tool-free element changes for fast, straightforward servicing on the water or at the dock
- Compatible with optional vacuum gauge: provides a real-time visual indicator of filter condition and remaining service life
- Optional in-filter heater compatibility: cold-weather starting aid available for 12 VDC and 24 VDC systems
- SAE J1926 O-ring sealed ports: reliable, leak-resistant fuel connections using a widely supported industry-standard thread design
- Broad temperature range: performs reliably across a wide range of ambient and fuel temperature conditions
- Replaceable elements in three micron ratings: allows the filter to be configured for primary or secondary filtration duties
 Racor 500FG Turbine Series Instructions
Racor Port Thread Information
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