Installation manual for Filtek filtration system on diesel generators. The Filtek Solution comprises:- Oil canister connected in by-pass mode to the generator. Fuel Canister connected in-line (either before or after the fuel pump) 1mircon filter elements (same for both oil and fuel) Optional – auto-oil dispenser to maintain oil sump levels on older generators

1. Installation Manual: Filtek Filtration Systems
Introduction
General
Due to the varying design of diesel generators (DG) themselves and the associated sound
proof canopy no two installations may ever be 100% identical. As such this manual is
designed to act as a comprehensive guide to ensure correct installation and connections of all
Filtek components.
Should the variances of your particular DG not be present in this manual the same principles
illustrated must be applied.
The OEM Oil and fuel filters are complimented by Filtek and not replaced by Filtek.
The table below should be followed in sequence
Table of Contents
1. Verify installation kit components
2. Indentifying a mounting location
3. Determining the height of a base mounting plate
4. Oil Canister installation and connections
5. Fuel Canister installation and connections
6. FAD installation and connections
7. Testing and commissioning
8. Trouble shooting the system & FAQ’s
Superior Filtration Solutions
Page 1

2. 1) Installation Kit Components (supplied)
Prior to commencement of any installation verify that the kit components been hoses, adaptors,
clamps and connectors are present and accounted for as per below listing
Note: for large scale deployment on a specific generator model the hoses lengths and JIC connect
angles must be specified in advance. This will then be made to order.
Kits components are supplied separately for the oil canister, fuel canister and FAD.
1.1 Oil Canister - Kit components
Website URL: www.filtek.co
Contact email: sales@filtek.co
Contact cell : +27 72 059 9363
+27 83 451 3647
* Illustrations show variations of the same part NOT quantities
Page 1

3. 1.2 Fuel Canister - Kit components
1.3 Auto-Oil Dispenser (FAD) - Kit components
* Illustrations show variations of the same part NOT quantities
* Illustrations show variations of the same part NOT quantities
Page 3

4. 2) Indentifying a mounting location
The best option is to take both the Oil and Fuel canisters to the generator itself. If a FAD is to be
fitted then this part should also accompany the initial survey. There are no real prerequisites for
the installation of both the Oil and Fuel filters , however the FAD has a very specific height
requirement. If you intend to fit a FAD pls see section #3.
Of the options listed below Filtek recommends #2.1 local manufacture of a base mounting plate
and that it is manufactured to the correct height for a FAD, irrespective if one will be installed
initially. This will ensure the entire base mounting plate remains future proof.
Canister Mounting Options
2.1. Option 1_Base mounting plate. This plate must be locally manufactured and is designed
to fit within the generator canopy itself. The Oil canister, Fuel canister and FAD will mount onto
this base plate. To avoid excessive vibration the base plate is mounted to the base (frame) of the
generator and not the generator itself. A template drawing of a typical base plate can be provided
upon request .
Base mounting plate
Below is a illustration of an alternative base mounting plate option. This option is more
elaborate and expensive to manufacturer than the above and therefore not
recommended.
Page 4

5. 2) Indentifying a mounting location (cont)
2.2. Option 2_Canopy mount
Should a suitable mounting base plate not be viable the canisters can be directly mounted onto
the sound proof canopy itself. This will require holes to be drilled into the canopy itself and
therefore the use of large washers are recommended.
Below is illustrations of such installations. The hose connection to the canisters are all straight.
2.3. Option 3_Outside the canopy
In the case where the installation is required solely for trial purposes meaning the system will be
decommissioned upon conclusion of the 1,000hr trial, mounting of the canisters outside may be
considered. The hoses may then be fed through the vents of the canopy which will still allow the
canopy to be locked. This method is of course not visually appealing and should be considered
temporary in nature, ‘for trial purposes only’.
2.4 Other mounting options
The services of a mechanical engineer are recommended to assist with the design of a base
mounting plate. The base plate is only required to be designed once per generator model/ canopy
type. A detailed database of the above should be kept for future records when installing Filtek
systems on a variety of generators.
Mounting options are finite so above only serves as conceptual ideas. Filtek recommends option
#2.1 due the fact it is acceptable in appearance and allows for both canisters and FAD mounting.
When large scale deployment takes place on a the exact same DG’s the correct hose lengths and
JIC connector angles must be specified upon order.
Canister is mounted with its
bracket in the vertical
position. Hose connections
are straight.
Canister is mounted with its
bracket in the horizontal
position. Hoses connections
are 90 degrees.
Page 5

6. 3. Determining the height of a base mounting plate
When recommended mounting option #2.1 is selected the height of the mounting base plate
is determined by the ‘principle of operation’ of the FAD itself.
This measurement only has to be taken once per generator / canopy type so ensure record
keeping for future deployment.
3.1 Ensure the generator has a ball valve connected to the sump plug.
3.2 Connect a 1m clear hose to the free end of the ball valve and ensure the open end of the
clear hose is cable tied to well above the estimated oil level in the sump.
3.3 Ensure the generator oil is at the correct level as specified by the OEM.
3.4 Open the ball valve and allow the oil to fill the clear hose.
3.5 Measure the height of the top of the oil level in the hose to the OEM base mount of the
generator itself onto which the locally manufactured base mounting plate will be bolted.
3.6 Write down the height and perform the simple calculation below to determine the height
of the base mounting plate .
This is height X.
3.7 Z is the height of the FAD above the base mounting plate. Z is 55mm for plastic type and
25mm for the Aluminium type.
X minus Z = Y base plate height
Sump
correct oil
level
Clear hose
DG mounting DG mounting
X
Y
Z = 55 or 25mm
Locally manufactured base mounting
plate for Filtek. Y is the base plate
height
Ball valve
Z = 25mm
Z = 55mm
FAD type A - Plastic
Z is 55mm
FAD type B - Aluminium
Z is 25mm
Note : bracket between brass lock nuts
Mount to DG base, not
after engine shock mount
to avoid excessive
vibration.
Page 6

7. 4.0 Oil Canister Installation and connections
This section assumes a suitable location has been identified for the Oil canister which has now
already been mounted.
The following aspects will be covered in this section:-
4.1 Connections from the Oil canister
4.2 Connections to the generator
4.2.1 High pressure output source for the generator. (Oil canister ‘input’)
4.2.2 Low pressure return to the sump. (Oil canister ‘output’)
Note: The Filtek Oil filter does NOT affect generator oil pressure due to the very small orifice on
the input which prevents any such change. A simple test can confirm this. Connect a ball
valve to the input of the oil canister. Run the generator for a few minutes to operational
temperature with the ball valve open. Check the filter is function correctly by checking that it
is hot (caution: same temperature as engine). Whilst running open and close the valve while
monitoring engine pressure. A small change may be noticed upon opening but will return to
normal within a few seconds once the oil canister is full again and has stabilised.
Element gauge (element resistance)
Input diffuser (pressure limiter)
Pressure regulator (max 3bar)
Output (return to generator)
Mounting bracket
4.1 Connections from the Oil canister
The canister incorporates the following:-
1. Input diffuser - contains a very small orifice so as NOT to affect engine oil pressure or
void OEM warranty in anyway.
2. Pressure regulator – limits internal pressure to maximum of 3bar. Excess pressure will
be ‘bypassed’.
3. Element gauge – measures the resistance between the input and output. (It is not a
measure of engine pressure). As the element becomes saturated with contaminants so the
pressure on the gauge will increase. High viscosity fluids will naturally present more
resistance. The gauge is effectively a visual inspection of the condition of the element.
Normal operation would be in the green area. High readings will indicate the filter element
is blocked and severely restricting oil flow - no longer working effectively. Action: element
replacement due.
Connect part #3 Adaptor - 1/4"BSP * 1/4"JIC to the canister output
Connect part #4 Adaptor - 3/8" BSP * 1/4"JIC to the canister input Page 7

8. 4.2 Connections to the generator
4.2.1 High pressure output source for the generator. (Oil canister ‘input’)
In order for the oil filter to function correctly a high pressure (>2bar) output from the engine
is required. This is normally achieved by adding a T-piece (part no #6) to the oil sender unit
and ‘tapping off’ a connection. Several other options exist such as using a sandwich adaptor
or any alternate high pressure points.
4.2.1.1 Option 1_from Oil Sender unit. Locate the oil sender unit within the generator
and follow the below step for step instructions. While all sender units are not identical in
shape size and location the principle will remain the same for all generator models.
a) Remove the sender unit wiring and unscrew the unit from the generator block
b) Join and tighten parts # 5, 6 & 7 together. These can be fitted in any combination to
ensure the sender unit does not protrude and block the canopy door etc.
c) Fit the part #5 to the hole in engine block left by removing the sender unit. Note if it
does fit correctly you may to use either a BSP or NPT fitting.
d) Reconnect the sender unit to the to open end of part #6 and reconnect the wiring.
Part #5 to engine block where sender was removed
Part #6 determine best angles to connect parts #5 & 7
Part #7 connection to Oil canister input (part #4)
Refit the sender unit
d) If a generator already has a T-piece then a 4 way connector is recommended.
e) Below are illustrations of completed connections for the high pressure output
High pressure hose part #8 or 9
4.2.1.2 Option 2_using a sandwich adaptor. A suitable sandwich adaptor which fits between
the OEM spin on filter and its housing on the engine may also be used.
4.2.1.3 Option 3 _other. Several other suitable places also exist on a per generator type . Pls
consult a qualified technical staff before proceeding.
Page 8

9. 4.2 Connections to the generator
4.2.2 Low pressure return to the sump. (Oil canister ‘output’). As such no recommended
point for oil return exists but is rather a case of finding the most suitable low pressure return
point anywhere on the generator. In the rare case that none exist the return may be via the
sump connection. However if a FAD is to be installed this causes excessive ‘plumbing’ but
remains a effective solution.
Certain blanking plates and grub screws can be removed to determine if they provide a return to
the sump. If not sure consult the OEM of qualified technical staff.
Below are illustration of various suitable oil return points. Grub screws are generally the best if
they exist. Blanking plates may also be removed and a thread tapped into them to accommodate
a adaptor similar to part # 3, 4 & 7.
Grub screw type return
Alternate Dipstick return
Certain OEM’s also provide for a dip stick connection on either side of the generator. Using the
adaptor plate provided the alternate side can be used. In this case all connections must be made
prior to screwing the adaptor back into place on the engine block. If not done in this sequence the
adaptor may bend when the hose connector is tightened and cause an oil leak.
Blanking plate type return
Tap a thread in the blanking plate to
accommodate part # 3, 4 or 7
Oil return from canister
FAD connection
Oil service drain
Sump type return
When deploying the sump type return it is
recommend to get a 4 way BSP adaptor and to
install a small section of flexible hose from the
actual sump plug. This will ensure less stress on
the sump plug due to vibration.
Page 9

10. 5. Fuel Canister and Connections.
This section assumes a suitable location has been identified for the Fuel canister which has now
already been mounted.
The fuel installation is relatively simple and only requires that a decision be made to mount the
filter before or after the fuel pump. Filtek recommends the filter be mounted before the fuel
pump as this will extend the life span of the pump. The only issue is that the fuel canister must
be manually filled with diesel fuel and the engine ‘primed to remove any air’ before starting.
Effectively the fuel canister connections inserts between the existing fuel line which supplies the
generator. The Fuel canister must be mounted after the water separator which is normally
located at the bulk tank outlet.
The following aspects will be covered in this section:-
5.1 Connections from the fuel canister
5.2 Connections to the generator and fuel supply
5.2.1 Fuel from the bulk / day tank to the canister. (Fuel canister ‘input’)
Disconnect the hose from the fuel supply to the generator and replace with hoses
supplied in the installation kit. Use the hose clamps supplied to ensure a tight seal.
5.2.2 Fuel to the generator. (Fuel canister ‘output’)
The hose to fuel pump should already be disconnected as it is the same hose as
above. Replace with hose supplied. Use the hose clamps supplied to ensure a tight
seal.
Input (from bulk or day tank)
Output (to generator)
Mounting bracket
Connect part #12 Adaptor - 1/4"BSP * 1/4"JIC to the canister output
Connect part #12 Adaptor - 1/4" BSP * 1/4"JIC to the canister input
Bulk tank with water trap
Fuel connection without Filtek
Fuel connection with Filtek.
Use supplied fuel hoses and
clamps
Page 10

11. NB: The hose from the FAD must never be
higher than the FAD connection itself.
In most installations the hose from the FAD
will have a slight downward curve towards
the ball valve connections which is correct.
6. FAD Installation and Connections.
This section assumes a suitable location has been identified for the FAD which has now already
been mounted. As mentioned the height of the FAD relative to the correct oil level in the sump is
critical.
The following aspects will be covered in this section
6.1 Ensuring correct FAD hose levels
6.2 Connecting the ball valve system. This system will create a connection to the FAD and
provision for engine oil drain from the sump. If applicable oil return may also form part of
this connection.
6.1 Ensuring correct FAD hose levels
As illustrated on page 6. Test that the height X measured is equal (+/5%) to the dashed green
line level of the FAD. Once correct you may proceed with the connections.
The FAD utilises a gravity feed system. The hose connection from the FAD to the ball valve must
comply with the below.
6.2 Connecting the ball valve system.
Connect the listed parts as illustrated below. Filtek recommends that the ½’ nipple part #18 and
hose part #21 be used as opposed to the part #19 which is shipped with all FAD’s. If however part
#19 and the supplied clear hose are used they must be fitted correctly to ensure a seal.
Nipple to FAD / black hose/ ball valve
part #18 / part #21 / part#18
Connect to engine sump. If the sump already has a ball
valve it should remain. Filtek recommends a short flexible
hose to avoid excessive vibration. Part #16
Ball valve part #17
Nipple part # 18
Hose part #21
Oil drain for maintenance. Extend
outside of canopy. Insert a bolt and
hose clamp to avoid leaks
Page 11

12. Drain ball valve is ‘normally CLOSED’ and is only opened when
conducting scheduled maintenance to drain the oil. Note the
hose is plugged with a bolt and hose clamp to ensure no
leakages.
6.2 Connecting the ball valve system (cont).
Upon connection of the ball valve system the installation should resemble the illustration below.
Note the system is cable tied to the generator chassis and NOT directly connected to the sump.
Connect to the FAD using either clear or black mining hose. Under Normal operation this ball
valve is OPEN. If the generator has a OEM ball valve this may remain and must also be OPEN.
Ensure this valve is closed when conducting scheduled maintenance to drain the oil.
FAD valve ‘normally OPEN’ (OEM valve ‘OPEN’)
oil drain (extend outside canopy).
Installation staff verifying the FAD height.
In this case the base mounting plate was too low and the
supplied FAD bracket used to increase the FAD height
FAD been filled. Note the silver lid does NOT screw off.
The FAD plunger must be hand tightened only.
Page 12

13. 7. Testing and commissioning
Prior to switching on the generator ensure the following checks:-
7.1 Check all the JIC (37° flare) hose connections are tightened as recommended.
This connection is widely used in hydraulic systems. When the straight threads are engaged, the
37° male seat seals on the 37° female flare seat. A 37° fitting body will accept both inch and
metric tube by changing the sleeve. The 37° adaptor body and nut are available with inch and
metric hex, as well as a variety of port end configurations.
Flats From Finger Tight
(F.F.F.T.)
is a Turns Method that counts
the number of hex flats past
the finger tightened position =
2 turns
Thread Size Nom. Size (in) # of Thrds per Inch
Male Thread outer
diameter (in)
Assembly
Torque
(in-lb)
Assembly Torque
(ft-lb)
Tube
Connection
FFFT
4 1/4 20 7/16 130 ‐ 150 11‐13 2
7.2 Neaten the installation. Any excess hose may be rolled and cable tied. Avoid vibration
contact areas as these may chaff the hose over time.
7.3 Diesel fill. Remove the Fuel canister lid and fill it with diesel taken from the storage tank. The
engine must now be primed to remove any air from the system.
7.4 Oil Fill canister. Remove the Oil canister lid and fill with the same oil which is been used in the
generator itself. Depending on the model Oil canister a extra 0.8 to 1.2 litres may be required.
7.5 Oil Fill – FAD. Remove the small oil pin from the FAD and fill with oil. (fill via the small
diameter pin and not the whole lid, it does not unscrew). Assuming all the levelling is done
correctly the FAD may now be tested. Use a clean container and remove 1litre of oil via the ball
valve system from the sump. The FAD should now slowly start to dispense oil back into the sump.
Note it is only a trickle fill and may take several minutes to dispense 1 litre. Once concluded
successfully return the oil back to the generator. If the FAD does not seem to be operating correctly
pls see section #8 Trouble shooting. If the engine is a closed system meaning the sump has limited
pressure within it also see section #8.
7.6 Start the generator and check for all leaks etc.
7.7 Replacing filter elements. Pls see the label instructions on the next page.
FAD been filled. Note the silver lid does NOT screw off.
The FAD plunger must be hand tightened only.
Page 13

14. Superior Filtration Systems
Part number FC-1000
http://www.filtek.co sales@filtek.co
FUEL CANISTER
* Use only Filtek RE-1000 element
RECOMMENDED TIMEPERIOD FOR REPLACEMENT
Element Replacement:
Turn off the engine
and wait 5 minutes for
levels to settle. Loosen
‘T’ screw anti
clockwise and remove
the lid and rubber
seal.
Extract the element
from the canister. Use
the extractor tool
supplied via the
security belt. The
element may rotate
back and forth for
ease of removal.
Load a new element
(security belt face
up). Push down to
bottom of the canister.
Inspect and reposition
the rubber seal onto
the canister (not the
lid).
Fill the canister with
fuel to just below the
rubber seal. Prime the
fuel pump. Hand
tighten the ‘T’ screw.
Insert the used
element in bag
provided for disposal.
Step 2.
Step 3.
Step 4.
Step 1.
Replace element every +1,000
runtime hours and conclude a
standard service. Should interval not
be achieved, clean the bulk fuel tank.
Superior Filtration Systems
Part number OC-1000
http://www.filtek.co sales@filtek.co
OIL CANISTER
* Use only Filtek RE-1000 element
RECOMMENDED TIMEPERIOD FOR REPLACEMENT
Replace element every 1,000 runtime
hours and conclude standard service.
Monitor gauge to indicate element
replacement due.
Element Replacement:
Turn off the engine
and wait 5 minutes for
levels to settle.
Warning HOT - use
gloves. Loosen ‘T’
screw anti clockwise
and remove the lid
and rubber seal.
Extract the element
from the canister. Use
the extractor tool
supplied via the
security belt. The
element may rotate
back and forth for
ease of removal.
Load a new element
(security belt face
up). Push down to
bottom of the canister.
Inspect and reposition
the rubber seal onto
the canister (not the
lid).
Fill the canister with
new oil to just below
the rubber seal. (do
not overfill). Hand
tighten the ‘T’ screw.
Insert the used
element in bag
provided for disposal.
Step 2.
Step 3.
Step 4.
Step 1.
Page 14

15. 8. Trouble shooting the system & FAQ’s
The following aspects will be covered in this section:-
8.1 Trouble shooting - Fuel System
8.2 Trouble shooting – Oil System
8.3 Trouble shooting – Filtek Auto-Oil Dispensing System
8.3.1 FAD principle of Operation on a closed generator system
8.1 Trouble shooting the fuel system. Assuming no leaks and correct connections very little
can go wrong with this system.
a) Fuel starvation (blocked element) The engine is not getting sufficient fuel. Switch off
the engine and do a physical inspection of the Filtek replacement element by
removing the canister lid. If the element is clogged and the generator has only been
running for a few hours the bulk tank is in urgent need of cleaning. Do not by-pass
the fuel filter even in the case of emergencies as this very contaminated diesel fuel
will most likely block the injectors causing significant down time and costs. In
emergencies first pump out as much of the contaminants as possible from the bottom
of the bulk tank and replace the element. Replacing the element will only provide a
temporary solution and will most likely block again but should provide sufficient time
and protection for the bulk tank to be cleaned.
b) Fuel starvation (flow rate). If the engine is not getting sufficient fuel and the
replacement element is clean then the generator has exceeded the fuel canister flow
rate. Add another fuel canister in parallel to the existing unit, this will effectively
double the flow rate.
c) Fuel starvation (OEM filter). In instances where Filtek was installed at an existing
problematic site, some contaminated fuel may be present in the system between
Filtek and the OEM spin on filter. Purge and replace OEM filter. The average OEM
spin-on filter is around 30 micron while Filtek offers 1 micron filtration. This effective
places very little or no work load on the OEM filter hence its ability to now remain for
1,000hrs.
Taking a fuel sample from a existing storage tank will often result in a bit of a ‘shock’. Diesel will
absorb the first small quantity of water it comes in contact with known as ‘emulsified water’ –
Filtek will remove this. However larger contaminants and quantities of water will settle at the
bottom of the tank which is the fuel supply to the generator. Using a hand pump remove this
layer and preferably clean the entire bulk tank.
Hazed fuel
Bacteria
Water and sludge
Hand pump to remove water and
sludge from the bottom of a bulk tank.
Page 15

16. 8.2 Trouble shooting the Oil system. Assuming no leaks and correct connections again not
much can go wrong with system.
To ensure the oil filter is working correctly after a few minutes of operation touch the canister
(caution HOT), it should be the same temperature as the engine. This will indicate correct oil flow.
The gauge on canister known as the ‘Element Gauge’ and measures the resistance between the
input and output. (It is not a measure of engine pressure). As the element becomes saturated
with contaminants so too will the pressure gauge reading will increase. High viscosity fluids will
naturally present more resistance. The gauge offers a visual inspection of the condition of the
element without opening the canister. Normal operation would be in the green area. High
readings will indicate the filter element is blocked and severely restricting oil flow - no longer
working effectively. Action: element replacement due.
Q: Does Filtek void my OEM warranty or change engine oil pressure
in anyway.
A: NO it does not.
The Filtek Oil filter does NOT affect generator oil pressure due to the very small orifice on the
input which prevents any such change. A simple test can confirm this. Connect a ball valve to
the input of the oil canister. Run the generator for a few minutes to operational temperature
with the ball valve open. Again you can check the filter is function correctly by checking that it is
hot same temperature as engine. Whilst running open and close the valve while monitoring
engine pressure. A small change may be noticed upon opening but will return to normal within a
few seconds once the oil canister is full again and has stabilised.
8.3 Trouble shooting – Filtek Auto-Oil Dispensing System. Assuming no leaks and correct
connections :-
a) FAD is over filling. The FAD is dispensing oil above the OEM prescribed level. In this case the
FAD is mounted to high. Often it is best to leave the generator off and allow the FAD to
continue to dispense oil until it stops. This over fill can then be measured on the dipstick and
translated to the FAD’s height decrease.
b) FAD is not working (align centre pin). Remove the centre pin at the top of the FAD and ensure
it is neatly seated in the reciprocal void. When the pin is removed from the FAD it will
disengage and not dispense.
c) FAD is not working (low level). If the FAD is not dispensing oil and the pin is correct the FAD
may to too low. Recheck all your height measurements or continue to remove oil from the
sump in small increments until the FAD’s starts to dispense. Via the dipstick this will provide
the height by which the FAD must be increased.
a) Oil from the engine is pushing the FAD level up. This condition will most likely indicate a
‘closed engine system’ which can often be confirmed from the manufacturer or indentification
of a breather at the top of the engine cover. For closed system a ‘aluminium non breather’
type FAD is recommended illustration bottom of page #6. For these system the principle of
operation of the FAD is slightly varied.
See 8.3.1 FAD principle of Operation on a closed generator system
Page 16

17. 8.3.1 FAD principle of Operation on a closed generator system
Some generators have a ‘closed’ oil system meaning there is pressure present in the sump when
the generator is running. Certain engine can be regarded as a high internal sump pressure which
increases the level of the sump by up to 10mm between the off and running conditions.
full
low
65mm
10mm full
low
65mm
1) Generator ‘off’ – sump full 100% 2) Generator ‘running’ – sump full 100%
FAD – NOT dispense
10m
m
45mm
Actual sump level (if
Generator where
off)
4) Generator ‘running’ – sump 80%
full
low
FAD – dispenses OIL
Actual sump level (if
Generator where
off)
FAD – dispenses OIL
FAD – dispenses OIL
3) Generator ‘running’ – sump @ 90%
FAD – NOT dispense
10mm
full
low
55mm
Actual sump level (if
Generator where
off)
FAD – dispenses OIL
Page 17