MANN+HUMMEL MCR Series User manual

Version 06/14_EN
MANN+HUMMEL
MANN+HUMMELMANN+HUMMEL
MANN+HUMMEL
Coolant Reservoir
Coolant ReservoirCoolant Reservoir
Coolant Reservoir
MCR
MCRMCR
MCR
Installation and maintenance instructions
Installation and maintenance instructionsInstallation and maintenance instructions
Installation and maintenance instructions

2 MANN+HUMMEL Industrial Filtration

Content
MANN+HUMMEL Industrial Filtration 3
List of contents
List of contentsList of contents
List of contents
1 Introduction ........................................................................................................................... 4
1.1 Manufacturer and originator.................................................................................................... 4
1.2 Guarantee and warranty.......................................................................................................... 4
1.3 Disclaimer................................................................................................................................ 4
1.4 Design outline.......................................................................................................................... 5
1.4.1 Lists......................................................................................................................................... 5
1.4.2 Handling instructions .............................................................................................................. 5
1.4.3 Safety notices.......................................................................................................................... 5
2 Safety...................................................................................................................................... 6
2.1 Basic safety instructions.......................................................................................................... 6
2.2 Intended use............................................................................................................................ 6
2.3 Unintended use....................................................................................................................... 7
2.4 Equipment marking ................................................................................................................. 7
2.4.1 Notices on device (pressure cap)............................................................................................7
2.4.2 Name plate (example will include) .......................................................................................... 7
3 Technical data ....................................................................................................................... 8
4 Scope of delivery................................................................................................................... 8
5 Assembly ............................................................................................................................... 9
5.1 Specific safety instructions...................................................................................................... 9
5.2 Install coolant reservoir ......................................................................................................... 10
5.3 Sensor connection................................................................................................................. 13
5.3.1 Electrical spezification .......................................................................................................... 13
5.3.2 Configuration......................................................................................................................... 13
5.3.3 Connection diagramm ........................................................................................................... 13
6 Checking .............................................................................................................................. 14
6.1 Specific safety information .................................................................................................... 14
6.2 Check function....................................................................................................................... 14
7 Maintenance......................................................................................................................... 15
7.1 Specific safety information .................................................................................................... 15
7.2 Maintenance work ................................................................................................................. 15
7.3 Replace coolant reservoir...................................................................................................... 16
8 Disposal................................................................................................................................ 17
8.1 Specific safety instructions.................................................................................................... 17
8.2 Coolant disposal.................................................................................................................... 17
8.3 Coolant reservoir disposal..................................................................................................... 17

Introduction
4 MANN+HUMMEL Industrial Filtration
1Introduction
These installation and maintenance instructions form part of the scope of delivery. They must
remain easily accessible through the entire life cycle of the product.
We reserve the right to change the designs outlined in these installation and maintenance
instructions as a result of further technical developments.
Reprinting, translation and any type of reproduction, in whole or as extracts, require written
approval from the originator.
Copyright is retained by the originator.
These installation and maintenance instructions are not covered by any amendment service.
The latest version at any time can be obtained from the manufacturer.
1.1 Manufacturer and originator
MANN+HUMMEL GmbH
Business Unit Industrial Filtration
Brunckstraße 15
67346 Speyer
Fon: [phone]
Fax: [phone]
Internet: www.mann-hummel.com
E-Mail: [e-mail]
1.2 uarantee and warranty
Information on warranty periods and general terms and conditions are available from the
manufacturer or under www.mann-hummel.com.
The guarantee and warranty cease to apply if:
– the product is changed without the manufacturer’s approval.
– the installation and maintenance instructions are not adhered to.
– spare parts and accessories other than those supplied or approved by the
manufacturer are installed and removed.
– the product is improperly handled.
1.3 Disclaimer
This manual is intended as a guide only; the manufacturer cannot be held responsible for the
performance of this product in its final application of which it has no control. The user must
satisfy themselves that the product is suitable for the application by their own testing and
approval in that application. Therefore the manufacturer cannot be held responsible for
equipment failure, damage or personal injury due to the product failure in the application.

Introduction
MANN+HUMMEL Industrial Filtration 5
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1.4 Design outline
1.4.1 Lists
Lists contain bullet points:
– Point 1
– Point 2
1.4.2 Handling instructions
Handling instructions which must be carried out in a defined sequence are numbered
consecutively:
1. Check coolant reservoir for damage.
2. Screw together coolant reservoir.
Handling instructions which do not necessarily have to be carried out in a defined sequence
are listed with bullet points:
• Fit return hose.
• Fit supply hose.
Additional information is marked with this symbol:
Further information in table.
1.4.3 Safety notices
A safety notice with the signal word ‘WARNING’ indicates a hazard to persons which could
result in serious injury or death.
A safety notice with the signal word ‘CAUTION’ indicates a hazard to persons which could
result in minor to moderate injury.
A safety notice with the signal word ‘NOTICE’ indicates possible property damage.
!
WARNING
!
CAUTION
NOTICE

Safety
6 MANN+HUMMEL Industrial Filtration
2Safety
The following points are to be observed when handling coolant reservoirs:
– The sub-chapter ‘Basic safety instructions’ lists fundamental rules when handling
coolant reservoirs.
– The ‘Specific safety instructions’ sub-chapters provide further safety instructions for
the relevant assembly tasks.
– Individual actions listed in the text contain safety instructions which refer to the
specific handling requirements.
2.1 Basic safety instructions
– These installation and maintenance instructions must be read in full before the
coolant reservoir is fitted.
– These installation and maintenance instructions must be available throughout
assembly on site.
– The user must ensure that assembly and maintenance of the coolant reservoir is
carried out only by qualified employees, e.g. automotive mechanics or persons with
related qualifications. Ensure that the qualified employee has been adequately
informed about installation and maintenance through these installation and
maintenance instructions.
– If there is visible damage to the coolant reservoir and its components, fitting and
operation must not take place.
2.2 Intended use
The coolant reservoir
– must only be used in technically perfect condition in accordance with its designated
use and the installation and maintenance instructions and only by safety-conscious
persons who are fully aware of the risks involved in its operation.
– must not be changed or adapted without the manufacturer’s approval.
– must only be used fully observing the installation and maintenance instructions and
adhering to the intervals and conditions for testing and general maintenance work.
– is designed for use with commercially available coolants.
– is suitable for use with screenwash fluid, the user must however ensure that such
screenwash material and additives have been approved for polypropylene containers.
– is designed for continuous operation.

Safety
MANN+HUMMEL Industrial Filtration 7
2.3 Unintended use
The coolant reservoir
– is not suitable for fuels, solvents, bases or acids.
– is not suitable for use with mineral or synthetic oils or oily substances.
– is not suitable for fluids intended for consumption.
– is not suitable for use as a pressure vessel in heating systems.
– must not be used in any other way than as described in these installation and
assembly instructions.
– must not be used if operating conditions (technical data, page 8) cannot be
maintained.
2.4 Equipment marking
2.4.1 Notices on device (pressure cap)
Observe installation and maintenance instructions.
Risk of injury
2.4.2 Name plate (example will include)
Manufacturer: MANN+HUMMEL
Model type: MCR15
Series number: 1001508S01
Series number: 2d barcode

Technical data
8 MANN+HUMMEL Industrial Filtration
4
5
1
2
3
3Technical data
4Scope of delivery
Check that the scope of delivery is complete and undamaged before assembly. Contact the
manufacturer in case of non-compliance.
Coolant reservoir (1), including 8 x M8
nuts (2) and pressure cap (3)
‘MAX’ label (4)
‘MIN’ label (5)
Material Polypropylene (PP)
Max. pressure 1,2 bar
Max. temperature * 100 °C
Min temperature* -20 °C
Pressure cap with pressure control valve Pressure control valve opens at 1 bar
Outlet connection DIN Standard ∅22 mm
Return connection DIN Standard ∅10 mm
Overflow connection underneath pressure cap ∅9,65 mm
Assemble reservoir M8 nuts
UV resistance Not UV resistant, cover to protect against
long-term UV radiation
* Applications outside the operating temperature range must be approved by the user or by
MANN+HUMMEL.

Assembly
MANN+HUMMEL Industrial Filtration 9
5Assembly
5.1 Specific safety instructions
Contact with coolant can lead to poisoning and chemical burns. Safety information on the
coolant manufacturer’s data sheet must be strictly adhered to when handling the coolant in
question!
– Harmful when swallowed.
– Seek medical advice immediately if swallowed, and retain packaging or label.
– Avoid contact with eyes and skin.
– Do not inhale vapours, ensure adequate ventilation.
– Wear suitable protective clothing and gloves when handling.
– Keep out of reach of children.
– The coolant and its packaging must be disposed of as hazardous waste.
Escape of coolant can cause environmental damage.
– Collect escaping coolant in a suitable vessel.
– Do not allow coolant to enter ground water, sewers or soil. Should this nevertheless
occur, inform the relevant authorities.
– Collect spilt or leaked coolant with non-flammable, absorbent material (sand, earth,
kieselguhr) and place in containers.
– For major leakage, pump coolant into suitable, correctly labelled containers and
dispose of in accordance with official regulations.
!
CAUTION
NOTICE

Assembly
10 MANN+HUMMEL Industrial Filtration
1
6
7
3
1
2
8
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5.2 Install coolant reservoir
Installation of coolant reservoir (1) is described using a horizontal 3.6 l container. The
appearance and arrangement of attachments may vary from the model shown.
The assembly steps are identical for all reservoir sizes and installation positions.
The coolant reservoir (1) must be protected against long-term UV radiation. If the installation
point is not under the bonnet, a suitable cover is to be used.
1. Establish suitable installation point.
Ensure that the outlet connection (6)
and the pressure cap (3) are at the
bottom and the return connection (7)
is at the top.
Select installation position so that the
coolant reservoir (1) is not damaged
through contact with other
components.
It must also be ensured that the hose
lines can be connected without kinks
or abrasion.
The coolant reservoir (1) must be
protected against long-term UV
radiation. If the installation point is not
under the bonnet, a suitable cover is
to be used.
2. Drill holes (∅min. 8.2 mm) to install
the coolant reservoir. Apply
corrosion protection to mounting
holes.
Hole spacings for the corresponding
coolant reservoir from the table
below.
Hole spacing
Volume of reservoir in ltr Dimension ‘a’ in mm Dimension ‘b’ in mm
1.5 l 70 mm 160 mm2.5 l
3.5 l
3.6 l 160 mm 182 mm5.6 l
8.0 l
3. Clean the contact surface of the
coolant reservoir (1).
NOTICE
NOTICE
1.5 to 3.5 litre
3.6 to 8.0 litre

Assembly
MANN+HUMMEL Industrial Filtration 11
12
1
10
11
12
12
9
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4. Check there are M8 nuts (2) at
all fastening points.
5. Screw coolant reservoir (1) with 4 x
M8 screws (8) of a suitable length.
Torque: 12 Nm
Select the screw length so that the
thread length in the coolant reservoir
(1) is max.14 mm.
6. Fit the feed hose (9), return hose
(10) and overflow hose (11) with
commercially available hose clips
(12) of a suitable size onto the
coolant reservoir (1).
The hose line must be positioned in
such a way that there are no kinks
or abrasion points.
See technical data (page 8) for the
diameter of the connecting piece.
If gripper clamps are not used,
attention must be paid to the
manufacturers torque settings for
hose clips.
Hose lines must be suitable for use
with coolants. If unsuitable hoses
are used, leakage in the cooling
system may occur.
NOTICE
NOTICE

Assembly
12 MANN+HUMMEL Industrial Filtration
1
4
5
3
13
1
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7. Position and fix ‘MAX’ (4) and ‘MIN‘
(5) for maximum and minimum
coolant levels in the coolant
reservoir (1). Ensure that markings
are clearly visible and cannot be
obscured by other fixtures.
The position of markings for
maximum and minimum coolant
levels are fixed by the machine
manufacturer.
8. Fill and vent the cooling system with
coolant as specified by the unit
manufacturer.
Fill the coolant reservoir (1) up to the
‘MAX‘ mark and close with the
pressure cap (3).
Escape of hot coolant can result in
serious burns.
Ensure that both O-rings (13) are
present on the pressure cap (3) of
the coolant reservoir (1) and that
they are undamaged.
Filling and venting the cooling
system must be carried out in
accordance with the unit
manufacturer’s instructions.
Incorrect filling or venting of the
cooling system may cause the unit
to overheat.
!CAUTION
NOTICE

Assembly
MANN+HUMMEL Industrial Filtration 13
A
B
5.3 Sensor connection
5.3.1 Electrical specification
5.3.2 Configuration
T
e
5.3.3 Connection diagramm
(A) Wire to the gauge
(B) Wire to the sensor
14
15
16
Max. Switched Current 0.5 A
Max. Switched Voltage 200 Vdc
Contact Rating 10 W
Max. Initial Contact Resistance 0.10 Ohm
Max. Carry Current 1.2 A
Min. Insulation Resistance 10
10
Ohm
Min. Voltage Hold-Off 200 Vdc
(
14
) Connector EPC E5937-001
(
15
) Contacts Tyco 2-1419158-5
(
16
) Approximate wire length from reservoir exit two-core, ca. 100 mm

Checking
14 MANN+HUMMEL Industrial Filtration
6Checking
6.1 Specific safety information
Escaping coolant can result in serious burns.
Pressurised coolant is hot.
Never open the pressure cap of the coolant reservoir when the coolant is hot.
In case of leakage or repair, turn off engine and allow the system to cool down.
6.2 Check function
1. Warm up the engine.
2. Check that connections are sealed.
3. Check there are no kinks or chafe marks on the hose lines.
4. Turn off engine and allow to cool.
5. Check coolant level and top up to required ‘MAX’ level with coolant if necessary.
!
WARNING

Maintenance
MANN+HUMMEL Industrial Filtration 15
7Maintenance
7.
..
.1 Specific safety information
Escaping coolant can result in serious burns.
Pressurised coolant is hot.
Never open the pressure cap of the coolant reservoir when the coolant is hot.
Contact with coolant can lead to poisoning and chemical burns.
Safety information on the coolant manufacturer’s data sheet must be strictly adhered to when
handling the coolant in question!
– Harmful when swallowed.
– Seek medical advice immediately if swallowed, and retain packaging or label.
– Avoid contact with eyes and skin.
– Do not inhale vapours, ensure adequate ventilation.
– Wear suitable protective clothing and gloves when handling.
– Keep out of reach of children.
– The coolant and its packaging must be disposed of as hazardous waste.
Escape of coolant can cause environmental damage.
– Collect escaping coolant in a suitable vessel.
– Do not allow coolant to enter ground water, sewers or soil. Should this nevertheless
occur, inform the relevant authorities.
– Collect spilt or leaked coolant with non-flammable, absorbent material (sand, earth,
kieselguhr) and place in containers.
– For major leakage, pump coolant into suitable, correctly labelled containers and
dispose of in accordance with official regulations.
7.2 Maintenance work
– Before operating the machine, always check the coolant level and there are no leaks
on the coolant reservoir.
Top up with coolant if necessary.
– Replace leaky/damaged components and hose lines.
– Regularly check antifreeze when operating in colder climates.
– Change coolant in accordance with the manufacturer of the application’s
specifications.
!
WARNING
!
CAUTION
NOTICE

Maintenance
16 MANN+HUMMEL Industrial Filtration
12
1
10
11
12
12
9
8
7.3 Replace coolant reservoir
1. Drain coolant as specified by the
manufacturer and collect in a
suitable container.
2. Remove hose lines (9, 10, 11) on
the coolant reservoir (1) by releasing
the hose clips (12) and pulling out
the hose lines (9, 10, 11).
3. Unscrew the 4 retaining screws (8)
on the coolant reservoir (1).
4. Remove coolant reservoir (1).
5. Installation: see chapter 5 for
assembly (page 8) and chapter 6 for
testing (page 14).

Disposal
MANN+HUMMEL Industrial Filtration 17
8Disposal
8.1 Specific safety instructions
Contact with coolant can lead to poisoning and chemical burns.
Safety information on the coolant manufacturer’s data sheet must be strictly adhered to when
handling the coolant in question!
– Harmful when swallowed.
– Seek medical advice immediately if swallowed, and retain packaging or label.
– Avoid contact with eyes and skin.
– Do not inhale vapours, ensure adequate ventilation.
– Wear suitable protective clothing and gloves when handling.
– Keep out of reach of children.
– The coolant and its packaging must be disposed of as hazardous waste.
Escape of coolant can cause environmental damage.
– Collect escaping coolant in a suitable vessel.
– Do not allow coolant to enter ground water, sewers or soil. Should this nevertheless
occur, inform the relevant authorities.
– Collect spilt or leaked coolant with non-flammable, absorbent material (sand, earth,
kieselguhr) and place in containers.
– For major leakage, pump coolant into suitable, correctly labelled containers and
dispose of in accordance with official regulations.
8.2 Coolant disposal
Coolant must be disposed of in accordance with the coolant manufacturer’s specifications and
applicable regulations.
– Dispose of in accordance with local regulations.
– May not be disposed of together with household waste.
– Do not empty into drains.
– Pass to special waste collector or take to hazardous waste collection centre.
8.3 Coolant reservoir disposal
The coolant reservoir must be disposed of in accordance with applicable regulations.
– Dispose of in accordance with local regulations.
– May not be disposed of together with household waste.
– Do not empty coolant residues into drains.
– Pass to special waste collector or take to hazardous waste collection centre.
!
CAUTION
NOTICE

MANN+HUMMEL GMBH, Business Unit Industrial Filtration
67346 Speyer, Germany, Fon [phone], Fax [phone]
E-Mail: [e-mail], Internet: www.mann-hummel.com