Cornell Diesel System’s Fuel Manager Diesel Filter Kits

Fuel Manager Diesel Filter Kits


Modern diesel engines are equipped with advanced high-pressure injection systems that can be easily damaged by poor quality fuel or, more frequently, contaminated fuel.

Common Rail (CR) diesel systems can run up to 40,000 psi. Many of these systems are intolerant to water and dirt particles and, if contaminated, result in costly engine repairs.

One way to provide better protection for your diesel engine is to install an additional fuel filter and water separator. Most CR systems only have one factory filter, so installing the additional filter is highly recommended, if not essential. Fuel Manager manufacture several options to meet each vehicle’s requirement.

Primary (Pre) Filter – 30 Micron


Plumbed before your factory fuel filter and rated at 30 microns, the Primary (Pre) Filter prolongs the service life of your factory OEM filter. A 30-micron filter will remove particles the size of 30 x 1000ths of a millimeter. This may sound very small, and it is, but not small enough to protect modern high-pressure CR fuel systems. Most factory filters on modern CR systems are rated at 10 micron.

Secondary (Final) Filter – 2 and 5 microns

Plumbed after the factory filter as a last line of defence, the secondary filter in both 2 and 5 microns will effectively remove any water or contaminants that make it past your factory filter. A 2-micron final filter will remove particles the size of just 2 x 1000th of a millimeter.


We stock a full range of fuel filter kits (including Hilux as shown for illustration only) designed specifically for easy install, to save you time and money. If you require more information please contact our friendly staff on 03 9267 8800

Pacific Power experiences the Cornell Difference

Pacific Power experiences the Cornell Difference

Pacific Power Engineering maintains power utilities for waste water, oil pumping stations, and generators in all mining sectors across the Pacific islands and southern Asian region. As a service provider to Pacific Power Engineering, Cornell Diesel Systems is currently servicing and maintaining all major Government power plant equipment and Pacific Power Ruston RKC diesel-powered generators across the Pacific islands.

Pacific Power Ruston RKC Generators

The Ruston RKC generator engine is in a power station on the island of Nauru, and is one of Pacific Power’s large frame engines that provides power for residential homes, businesses, airport and all major government buildings.

Pacific Power’s generators have a capacity of 2.9-megawatt output. Their Ruston RKC generators are periodically overhauled in two stages: cylinder heads are serviced at 6000hrs, and all other major parts and components are overhauled at 12000hrs.

Diesel Fuel Injection Services

All diesel fuel injection components are overhauled at 2000 running hours. All components are broken down in our ISO-certified, pressurised clean room and inspected by a fully-certified accredited technician.

Cornell Diesel Systems is proud to have the specialised knowledge required to service all large frame applications, providing end-to-end service of large frame power generator fuel systems across the Pacific region on behalf of Pacific Power.

HPD Catch Can

HPD Catch Cans

The HPD Catch Can is one of the simplest and most effective accessories you can fit to a turbo-diesel engine.

To meet ever stricter emissions regulations, manufacturers of diesel engines have used Exhaust Gas Recirculation (EGR), which diverts sooty exhaust gases back into the engine to be burned again, reducing particulate emissions.

The engine breather pipe sends air from inside the crankcase into the intake as well. The fine oil mist in this air combines with the soot from EGR to form a sticky deposit that builds up to the point that it affects the breathing of the engine, clogs EGR valves and jams turbo actuator flaps.

HPD has tackled this problem with a catch can that filters out damaging oil mist and condensation from the air entering the inlet passage. The HPD catch can does not vent to the atmosphere, so it’s compliant with Australian Design Rules and Standards.

The oil reservoir has a dipstick for easy monitoring of the oil level, and unscrews for easy emptying when required. The mesh filters require little maintenance – only occasional cleaning – so you don’t need to spend money replenishing filters.

Designed and manufactured in Australia from billet aluminium, HPD catch can kits come complete with laser cut brackets, silicon hoses, and all clamps and fasteners needed to complete a factory look fitment.

Benefits of using a Catch Can

  • Maintains vehicle performance, power and efficiency
  • Reduces carbon and oil build up in the inlet manifold
  • Stops oily residue build up in the intercooler
  • Ensures clean air is delivered to the engine
  • Protects turbo bearings from corrosion

Advantages of fitting a HPD Catch Can

  • Dipstick to check oil level
  • Washable filter (no need to replace)
  • 360° rotating inlet to assist fitment
  • Universal stainless steel fitment bracket
  • Easy step-by-step fitment guide
  • 100% Australian made and engineered


To find out more about HPD catch cans and why we recommend them over others, give our friendly sales team a call on 03 9267 8800.

Diesel Particulate Filters

What is a DPF (Diesel Particulate Filter)?

A DPF is used in diesel vehicles that comply with Euro-6 emission standards. The manufacturers use the DPF to filter, store and burn the soot particles that are emitted as a result of the combustion process of the diesel engine. DPF’s come in a common cylindrical unit. The DPF consists of silicon carbide. It can filter about 99% of solid particulate matter from the exhaust of a diesel engine. The soot particles or the carbon particles deposit on the filter channels are oxidised into carbon dioxide at exhaust temperatures above 600degC. Basic DPF’s are the single use type. You need to dispose or replace them when they get full, after accumulating ash and when regeneration is no longer possible.


What are Particulates?

Particulates are a form of carbon that accumulates in the exhaust system of the vehicle’s engine, originating from various leftovers that define what type they are. In term of vehicles, particulates are the minute solid particles of exhaust gases emitted from the engine. The engine emits these particulates mainly in the form of carbon or soot. The particulate matter forms a layer of carbon inside the exhaust system of the engine. This is the main reason why taking care of the exhaust system of the engine is so important. It is necessary to limit the quantity of emitted carbon particulates to prevent environmental pollution.


How does a DPF work?

The unfiltered exhaust flows through the DPF’S channels that open at the inlet end. The core contains porous walls of a ceramic honeycomb structure made of silicon carbide. The exhaust gases then enter into the channels that are open at the outlet end. The exhaust system takes away the exhaust gases. The DPF core retains the soot particles and later burns them off during the regeneration process. The ECU computes the amount of soot and ash accumulation in the DPF with the help of the DPF differential pressure sensor.


Components of a DPF

The temperature sensor upstream of the DPF detects the temperature of the exhaust before it enters the DPF. The integral resistor changes its electrical resistance according to the exhaust temperature and then sends a corresponding voltage signal to the ECU control unit. The control unit uses the voltage signal to monitor the rise in exhaust temperature before and during the regeneration process. The DPF differential pressure sensor detects the difference between the exhaust upstream and downstream of the DPF. The exhaust pressure sampling pipes – upstream and downstream of the DPF – detect the exhaust pressure difference. The pressure difference between the exhaust pressures upstream and downstream of the DPF acts on the piezo electric pressure sensor element. This produces a voltage which is passed into the ECU as a voltage signal.


What is Regeneration?

Regeneration is the process that burns off the soot particles accumulated in the DPF as C02. The regeneration takes place when the ECU detects a certain pressure difference in the DPF, then at a certain speed usually above 80kph the DPF temperatures will raise to about 600 degrees Celsius, causing the soot build up to burn away. This will continue until the pressures in the DPF fall back into specification. That is why it is recommended that a vehicle with a DPF be driven on a freeway at least 20 minutes every week to initiate a regeneration (please consult vehicle owner’s handbook).