MAHLE MCX-1 User manual

OPERATION MANUAL
OPERATION MANUALOPERATION MANUAL
OPERATION MANUAL
MCX
MCXMCX
MCX-
--
-1
11
1
Multiple Coolant Exchanger
Multiple Coolant ExchangerMultiple Coolant Exchanger
Multiple Coolant Exchanger
MAHLE A termarket Inc., RTI Division
MAHLE A termarket Inc., RTI DivisionMAHLE A termarket Inc., RTI Division
MAHLE A termarket Inc., RTI Division
10 Innovation Drive
York, PA 17402
800-468-2321
www.servicesolutions.mahle.com
Manual Number 035 82230 00
OFF
&OVER
FLOW
LOWERRADIATOR
OFF
EXCHANGEC
OOLANTOR
FILLR
ADIATOR&OVERFLOW
&OVERFLOW
LOWERR
ADIATOR
EMPTYWASTETANK
EXCHAN
GEC
OOLANT
&OVERFLOW
FILLRADIATOR
OFF
EMPTYWASTETANK

Page 1
TABLE OF CONTENTS
Component Description .............................................................. 2
Sa ety Precautions ...................................................................... 3
Set-up ......................................................................................... 4
Connection to Power .................................................................. 5
Lowering Coolant Level .............................................................. 6
Connecting to the Coolant System ............................................. 7
Special Hookups ......................................................................... 8
Coolant Replacement ................................................................. 9
Completing the Job .................................................................. 10
Changing Coolant Type ............................................................ 12
Emptying the Waste Tank ......................................................... 14
Replacement Parts .................................................................... 15
Waste Pump Impeller Replacement .......................................... 16
Flow & Wiring Diagram .............................................................. 17

Page 2
COMPONENT DESCRIPTION
Unpack all components and veri y quantities per this illustration.
Contact MAHLE i any items are missing or damaged.
Wand
New Coolant
Tank
Waste Tank
Small Adapter Hose
Large Adapter Hose
Small Hose Clamps
Large Hose Clamps
1-1/4
1-1/2
Large Step Adapters
Small Step Adapters
VALVE OPEN
1-3/4
VALVE CLOSED
1-1/4
1-3/8
1-3/8
1-1/2 1-3/4
Impeller & Gasket
OFF
&OVERFLOW
LOWERRADIATOR
OFF
EXCHANGECOOLANTOR
FILLRADIATOR&OVERFLOW
&OVERFLOW
LOWERRADIATOR
EMPTYWASTETANK
EXCHANGECOOLANT
&OVERFLOW
FILLRADIATOR
OFF
EMPTYWASTETANK

Page 3
SAFETY PRECAUTIONS
WARNING:
WARNING:WARNING:
WARNING: FAILURE TO FOLLOW THESE PRECAUTIONS CAN RESULT IN
FAILURE TO FOLLOW THESE PRECAUTIONS CAN RESULT INFAILURE TO FOLLOW THESE PRECAUTIONS CAN RESULT IN
FAILURE TO FOLLOW THESE PRECAUTIONS CAN RESULT IN SERIOUS
SERIOUS SERIOUS
SERIOUS
INJURY OR DEATH.
INJURY OR DEATH.INJURY OR DEATH.
INJURY OR DEATH.
C Read and understand the Operation Manual completely be ore operating this unit.
C Always wear proper eye and skin protection when operating and maintaining this equipment.
C Take precautions to keep clothing, hair, hands, hoses, etc. away rom all moving parts on the
vehicle.
C Automotive cooling systems can be under pressure and extremely hot. Allow the cooling
system to cool down and use extreme caution when removing caps and hoses.
C Coolants are poisonous to people and animals and are also corrosive. Clean up any spills
immediately.
CAUTION:
CAUTION:CAUTION:
CAUTION: FAILURE TO FOLLOW THE PRECAUTIONS AS OUTLINED IN THE OPERATION
FAILURE TO FOLLOW THE PRECAUTIONS AS OUTLINED IN THE OPERATION FAILURE TO FOLLOW THE PRECAUTIONS AS OUTLINED IN THE OPERATION
FAILURE TO FOLLOW THE PRECAUTIONS AS OUTLINED IN THE OPERATION
MANUAL CAN RESULT IN DAMAGE TO THE ENGINE, VEHICLE OR
MANUAL CAN RESULT IN DAMAGE TO THE ENGINE, VEHICLE OR MANUAL CAN RESULT IN DAMAGE TO THE ENGINE, VEHICLE OR
MANUAL CAN RESULT IN DAMAGE TO THE ENGINE, VEHICLE OR
EQUIPMENT WHICH WILL NOT BE SUPPORTED OR COVERED UNDER
EQUIPMENT WHICH WILL NOT BE SUPPORTED OR COVERED UNDER EQUIPMENT WHICH WILL NOT BE SUPPORTED OR COVERED UNDER
EQUIPMENT WHICH WILL NOT BE SUPPORTED OR COVERED UNDER
WARRANTY.
WARRANTY.WARRANTY.
WARRANTY.
C Do not allow waste coolant tank to over low. Immediately clean up any coolant spills. Damage
to the vehicle and equipment can result rom the corrosiveness o coolant.
C Continuous monitoring o the coolant replacement process is required.

Page 4
SET UP
The MCX-1 has two tanks (plus an extra New Coolant Tank) which are installed and
connected rom the rear. Quick connect couplers are mounted on the hoses which connect
these tanks to the MCX-1. A green hose connects to the small New Coolant Tank and a black
hose connects to the large Waste Tank.
1. Slide the New Coolant Tank to the rear and sit it on the loor.
2. Remove the tank cap and ill the tank with new coolant and water in the proportions
speci ied by the coolant supplier. The tank can be disconnected and moved to a bulk
storage and ill area i desired. A plug is provided on the cap to prevent spillage during
transport.
3. Replace the tank cap and position the tank in the MCX-1. Make sure the green hose is
securely connected. Slide the tank to the ront so the liquid level can be seen through the
ront panel slot.
4. Make sure the plug
Make sure the plugMake sure the plug
Make sure the plugs are removed rom the caps on
s are removed rom the caps on s are removed rom the caps on
s are removed rom the caps on the waste tank and the new
the waste tank and the new the waste tank and the new
the waste tank and the new
coolant tank. This is required or venting the tanks during operation.
coolant tank. This is required or venting the tanks during operation.coolant tank. This is required or venting the tanks during operation.
coolant tank. This is required or venting the tanks during operation.
5. Fasten the clips on the tank strap to secure the tanks in the MCX-1.
New Coolant Tank
Coupler
Green Hose
Quick
Green Hose
Black Hose
Tank Cap & Plug
(Small)
New Coolant
OFF
&OVERFLOW
LOWERRADIATOR
OFF
EXCHANGECOOLANTOR
FILLRADIATOR&OVERFLOW
&OVERFLOW
LOWERRADIATOR
EMPTYWASTETANK
EXCHANGECOOLANT
&OVERFLOW
FILLRADIATOR
OFF
EMPTYWASTETANK

Page 5
OFF
&OVERFLOW
LOWERRADIATOR
OFF
EXCHANGECOOLANTOR
FILLRADIATOR&OVERFLOW
&OVERFLOW
LOWERRADIATOR
EMPTYWASTETANK
EXCHANGECOOLANT
&OVERFLOW
FILLRADIATOR
OFF
EMPTYWASTETANK
CONNECTION TO POWER
The MCX-1 control panel is illustrated above. Note that the bottom o all three selector
switches has been pressed which turns all unctions o . Make sure all switches are o
Make sure all switches are o Make sure all switches are o
Make sure all switches are o
be ore connecting the battery cable clips to the battery o the vehicle.
be ore connecting the battery cable clips to the battery o the vehicle.be ore connecting the battery cable clips to the battery o the vehicle.
be ore connecting the battery cable clips to the battery o the vehicle.
WARNING:
WARNING:WARNING:
WARNING: Handle battery connection cable with extreme caution. Batteries generate
Handle battery connection cable with extreme caution. Batteries generate Handle battery connection cable with extreme caution. Batteries generate
Handle battery connection cable with extreme caution. Batteries generate
explosive gases during normal operation. Working in the vicinity o
explosive gases during normal operation. Working in the vicinity o explosive gases during normal operation. Working in the vicinity o
explosive gases during normal operation. Working in the vicinity o a
a a
a
lead
leadlead
lead-
--
-acid or other automotive battery is dangerous. Wear eye protection.
acid or other automotive battery is dangerous. Wear eye protection. acid or other automotive battery is dangerous. Wear eye protection.
acid or other automotive battery is dangerous. Wear eye protection.
Never smoke or allow a spark or lame in the vicinity o the battery. Do not
Never smoke or allow a spark or lame in the vicinity o the battery. Do not Never smoke or allow a spark or lame in the vicinity o the battery. Do not
Never smoke or allow a spark or lame in the vicinity o the battery. Do not
connect the black power clip to the negative post o the battery to avoid a
connect the black power clip to the negative post o the battery to avoid a connect the black power clip to the negative post o the battery to avoid a
connect the black power clip to the negative post o the battery to avoid a
spark.
spark.spark.
spark.
1. Veri y that all switches are in the o position.
2. Connect the red power clip to the A+@ (positive) post o the vehicle battery. The battery
must be 12 volt.
3. Connect black power clip to an engine ground (not the negative post o the battery).
..
.

Page
6
LOWERING COOLANT LEVEL
WARNING:
WARNING:WARNING:
WARNING: Coolant in the vehicle cooling system may be extremely hot and under
Coolant in the vehicle cooling system may be extremely hot and under Coolant in the vehicle cooling system may be extremely hot and under
Coolant in the vehicle cooling system may be extremely hot and under
great pressure. Wear sa ety glasses and use protective clothing and
great pressure. Wear sa ety glasses and use protective clothing and great pressure. Wear sa ety glasses and use protective clothing and
great pressure. Wear sa ety glasses and use protective clothing and
gloves. Use extreme caution when removing radiator cap and hoses.
gloves. Use extreme caution when removing radiator cap and hoses.gloves. Use extreme caution when removing radiator cap and hoses.
gloves. Use extreme caution when removing radiator cap and hoses.
1. Slowly and care ully remove the cap rom the radiator.
2. Remove cap rom over low container.
3. Attach the wand to the black hose. Close the valve.
4. Turn control valve to LOWER RADIATOR & OVERFLOW.
5. Press the top o LOWER RADIATOR & OVERFLOW selector switch to turn on pump.
6. Use the Wand to empty the over low container and lower the level o coolant in the radiator
to a level just below the upper hose connecting the radiator to the engine. Open valve on
wand as required.
7. Press bottom o LOWER RADIATOR & OVERFLOW selector switch to turn o pump.
8. Replace caps on the radiator and over low container.
Green Hose
Water
Radiator Overflow
Pump
Black Hose
Hose
Radiator
Wand Heater
Engine
Core
Block
O
FF
&OVERFLOW
LOWERRADIATOR
OFF
EXCHAN
GECOOLANTO
R
FILLRADIATOR&O
VERFLO
W
&O
VERFLO
W
LO
WER
RADIATOR
EMPTYWASTETAN
K
EXC
HANG
ECOOLANT
&OVER
FLOW
FILLRADIATO
R
OFF
EM
PTYWASTETANK
EMPTYWASTETANK
LOWERRADIATOR
&OVERFLOW
FILLRADIATOR&OVERFLOW
EXCHANGECOOLANTOR
EMPTYWASTETANK
OFF
FILLRADIATOR
&OVERFLOW
EXCHANGECOOLANT
OFF
LOWERRADIATOR
&OVERFLOW
OFF
VERY IMPORTANT
Open valve on want only w ile end is in fluid.
Do not suck air as t e pump may lose its prime.

Page
7
Connecting at Engine
Pump
Water
Radiator Overflow
Green Hose
Black Hose
Adapters
Step
Hose
Radiator
Block
Engine
Connecting at Radiator
Black Hose
Green Hose
Adapter
Block
Engine
Hose
Core
Heater
Step
Adapters
Adapter
Hose
Radiator Overflow
Pump
Water
Hose
Radiator
Core
Heater
OFF
&OV
ER
FLO
W
LO
WERRA
DIATOR
OFF
EXCHA
NGECOOLA
NTOR
FILLRADIA
TO
R&O
VERFLOW
&OVERFLO
W
LO
WE
RRADIATOR
EMPTYWASTETAN
K
E
XCHANGECOOLANT
&OVERFLOW
FILLRAD
IATOR
OFF
EMPTYWAS
TETANK
OFF
&OV
ER
FLOW
LOWERRADIATOR
OFF
EXCHANG
ECOO
LA
NTOR
FILLRADIA
TOR&OV
ER
FLO
W
&
OV
ERFLOW
LOWERR
ADI
ATOR
EMPTYWASTETA
NK
EXCHANG
ECOO
LAN
T
&
OVE
RFLOW
FILLRADIA
TO
R
O
FF
EMP
TY
WA
STE
TANK
CONNECTING TO THE COOLANT SYSTEM
The MCX-1 can be connected to the cooling system in either o the con igurations shown
below. The choice is dependent on the ease o accessibility to the hose connections.
1. Disconnect the radiator hose rom either the engine or the radiator.
2. Select an Adapter Hose with the same inner diameter as the radiator hose and connect at
the point the radiator hose was disconnected using a clamp.
3. Install Step Adapters in the Adapter Hose and the radiator hose using clamps. Make sure
the outside diameter o the Step Adapters is the same as the inner diameter o the radiator
hose.
4. Connect the Green and Black hoses rom the MCX-1 to the two Step Adapters as shown
in the ollowing illustration. See next page or special hookups.
See next page or special hookups.See next page or special hookups.
See next page or special hookups.
5. Open the valves on the two Step Adapters.

Page
8
Block
Engine
Adapters
HOSE
PINCH
Hose
Radiator
PINCH
HOSE
Overflow
Pump
Water
Step
Hose
Adapter
Heater
Core
SPECIAL HOOKUPS
Special Hookup 1 ) It may be necessary to reverse the hoses during the coolant replacement
procedure on the next page or systems with a reverse-connected
thermostat. See note a ter Step 6 on next page or the symptoms o this
situation.
Special Hookup 2) Some cooling systems do not have a cap on the radiator. Instead, there is a
single cap on the over low tank as shown in the illustration below.
The hoses to and rom the over low tank must be pinched using hose
pinching pliers during the coolant replacement procedure on the next page.
Failure to pinch these hoses will cause luid to be orced out o the vented
cap on the over low tank during the coolant replacement procedure.

Page
9
COOLANT REPLACEMENT
Once the MCX-1 is connected as described on the preceding pages it is ready to replace the old
coolant with new coolant.
Scales for t e tank
levels are graduated in
quarts and liters
1 Gallon = 4 Quarts.
1. Determine the capacity and type o coolant or the vehicle cooling system. Re er to the
vehicle Owner’s Manual.
2. Make sure the New Coolant Tank (le t slot on ront) is illed with the correct coolant and at
a level higher than the amount required to ill the coolant system to ull capacity.
3. Check the Waste Tank (right slot on ront) to make sure the level is low enough to accept
the ull capacity o coolant in the vehicle cooling system.
4. Turn control valve to EXCHANGE COOLANT.
5. Press the top o EXCHANGE COOLANT OR FILL RADIATOR & OVERFLOW selector
switch to turn on the pump.
6. Watch the level o coolant as it lowers in the New Coolant Tank. Press the bottom o the
EXCHANGE COOLANT OR FILL RADIATOR & OVERFLOW selector switch when it
reaches the correct level. This will stop the trans er o coolant.
Adapters
Radiator
Hose
Radiator
Black Hose
Green Hose
Pump
Overflow
Hose
Adapter
Step
Water
Heater
Block
Engine
Core
OFF
&OVERFLOW
LOWE
RRA
DIA
TO
R
OFF
EXCH
AN
GECOO
LANTOR
FILLR
ADIATO
R&OVERFLO
W
&
OVERFLOW
LOWE
RRA
DIATO
R EMPTY
WA
STETA
NK
EX
CHA
NGECOOLANT
&
OVE
RFLO
W
FILLRADIATO
R
OFF
E
MPTYW
ASTE
TANK
FILLRADIATOR&OVERFLOW
EXCHANGECOOLANTOR
EMPTYWASTETANK
LOWERRADIATOR
&OVERFLOW
EMPTYWASTETANK
OFF
FILLRADIATOR
&OVERFLOW
EXCHANGECOOLANT
OFF
LOWERRADIATOR
&OVERFLOW
OFF
If t e pump is running and new coolant level does not go down:
Try reversing t e connections of t e green and black oses.