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Discussion Starter · #1 ·
Hi folks,

I got into a very serious problem the other day.
I have a new Yanmar 4JH57 the new common rail engine. 300 hours on the clock. It has a new pre-filter replacing the Racor 500. The inlet on the new Yanmar pre-filter has a Banjo bolt where the fuel must turn at 90 degrees and go through a hole in the bolt about 1mm wide.


This turn gunked up and the engine stopped.... in a remarkably difficult and dangerous location with a contrary current of 5 knots and me being only able to sail at 1.3 knots - directly towards the rocks!!! With another 6 hours of current sucking me into the infamous Alderney race with currents up to 9 knots.

If it had stopped 15 minutes later there is no way I could have turned around and been able to sail into the current.

So I had a fun few hours trying to sail and locate the fuel fault.
Also the filter needs a spanner/wrench far larger than I have so I couldn't change the filter at sea!

On a brand new engine its not expected to stop!
Anyway I finally traced it back to the Banjo Bolt and its tiny hole. A tiny piece of orange plastic has gummed it up then crap built up around it.
I though a pre-filter was meant to suck anything out of the tank and filter it before the primary fuel filter mounted on the engine.

I do not want / and will not have this possible situation again. Cruising boats can often pick up dirty fuel (I've fuelled in Venezuela, Egypt, Oman, Indonesia, Malaysia etc) or some goop can get in or grow, no matter the additives etc.

My solution is to buy a new Racor 500 as a pre-pre-filter and to mount it in the aft cabin on the external riser for the bunk, adjacent but on the outside wall to the Yanmar filter. Thus I will be able to ensure gunk the size that blocked the Banjo Bolt will not cause a problem, and that I can visually see the Racor from the Saloon, and change that Racor filter in less than 1 minute.

I found the problem and cleaned the Banjo Bolt and was able to get back to harbour no problems... but by then another bit of gunk was in the bolt.
I pumped out the whole tank and filtered the fuel and its clean as a whistle.

I will upload a pic of the problem off my phone in a few moments... but heres a location snap of exactly where you do NOT wanna have the engine clag up.

Your comments appreciated.


Mark
 

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Discussion Starter · #3 · (Edited)
The black goobie bits are flattened.

I 'think' the orange it came in from a gerry can. Dunno how.

The filter show shows how much gunk I got out of the fuel tank. Negligible.

BTW, the passage was a major shake-a-thon and I only had about 50 litres of fuel in the tank, so classic stirred up sediment.

[most spelling corrected :) ]
 

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Discussion Starter · #5 ·
Lol Mark - either you've been sipping at the medicinal alcohol or your spell-checker has :)

I does look nasty - did that black stuff also make it past your filter? Is that electrical connection under the filter for the water-warning buzzer?
Spelling corrected :)

The black stuff was stuck in the Banjo Bolt before getting into the filter.

Yes, the wires below are for the water alarm. Its that part I cant unscrew at sea without a better tool.

With your dual racors:
Do 2 Racors slow down the fuel flow?
What micro filters are you using?

I was thinking the 30 micron... but if fuel flow isnt slowed down could I use 10 micron or even 2 micron?
With 2 micron the pre-filter and the engine mounted fuel filter would never need to filter anything.

Mark
 

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Discussion Starter · #11 ·
Crazy is right. I'd remove the whole thing and replace it with the Racor, rather than just add a Racor.
Yeah I think you're right. But I am wondering about the wires out of the yanmar filter that give the water warning. If they are not used does it effect the electronics in some way? I doubt it but I will ask before removing it.
Or I could just bypass the yanmar filter.
 

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Discussion Starter · #22 ·
Mark,

A question.

Does this troublesome Yanmar filter have a hand pump on its top? I think I see one in the picture. That might be a nice feature to retain if possible.

Is there a way to replace the banjo fitting with something more straight forward? I've had good success with a Parker dealer helping me out with odd fittings.
Yes to the pump on top, that's one reason to keep it as there is no hand operated pump near the final engine mounted filter, nor a bleed screw on the engine.

Re replacing the Banjo Bolt with a screw in barb fitting. I will investigate.

Thanks for the thoughts.
 

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Discussion Starter · #27 ·
Haven't been filtering fuel before it enters the tanks. Does anyone here do that? What do you use?
Nope. And I cant really as I often put another gerry can in at sea. My fuel tank is not so big so for cruising I always take, and rely on, 6 gerrys. I cant use a Baja filter when in a seaway with the chance of a wave over the deck.
 

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Discussion Starter · #43 ·
The new Racor going in.

The first photo shows the position in the aft cabin. Yes some guests might find it a little inconvenient...

The second pic shows the view from the Salon. I can keep a casual eye on it anytime. Plus I don't need to move cruising junk and the mattress to change filters.
 

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Discussion Starter · #54 ·
Thanks! This two year old post saved me a LOT of time.

Engine quit unexpectedly, did a quick search about these "new-to-me" filters and found this post. Sure enough, I had the same problem.

Thanks! Seahawk on the Chesapeake.

View attachment 139934
Glad I could be some help! ? ? ? ? ?

And honoured you joined just to say "Thanks" ☺

Mark
 
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