Mann+Hummel Preline Prefilters For Diesel Fuel Installation and Maintenance Manual

MANN+HUMMEL
PreLine
Prefilters for Diesel Fuel
Installation and Maintenance Manual
19 611 31 018 en 0112 Version 0112

MANN+HUMMEL PreLine
5.7 Troubleshooting ........................................... 21

Contact information 6 Technical Data ................................................... 22
6.1 PreLine 50 ................................................... 22
6.2 PreLine 150 and 100 ................................... 23
This installation and maintenance manual is a 6.3 PreLine 250 ................................................. 24
component part of the scope of delivery. It 6.4 PreLine 270 ................................................. 24
must be kept in a safe place and remain with 6.5 PreLine 420 ................................................. 25
the equipment in the event of resale. 6.6 PreLine 421, 601 ......................................... 25
7 Spare Parts ........................................................ 26
We reserve the right to make technical 7.1 Spare parts list, PreLine 50-250 filter head . 26
improvements to the products described in 7.2 Spare parts list, PreLine 50, PreLine 150/100
this installation and maintenance manual 27
without notification. 7.3 Spare parts list, PreLine 250 ....................... 27
7.4 Order number, complete filter...................... 28
Reprinting, translation and copying of this 7.5 Spare parts list, PreLine 270/420/600 filter
document, or extracts of it, by any means head including 271/421 ........................................... 29
requires the written approval of the publisher. 7.6 Spare parts list, PreLine 270, 420, 600 ....... 30
7.7 Spare parts list, PreLine 271 and 421 ......... 31
Copyright remains with the publisher. 7.8 Order number, complete filter...................... 32
This operating and maintenance manual is not 8 Technical Report ............................................... 33
subject to an updating service. 9 Related Documents .......................................... 33
10 Drilling Templates ............................................. 34
Information on the current status is available 10.1 2-hole flange (PreLine 50 to 250) ................ 34
from 10.2 4-hole flange (PreLine 270, 420, 600 or 271,
MANN+HUMMEL GMBH 421) 35
Industrial Filters Business Division 1 Foreword

Brunckstr. 15
D - 67346 Speyer This installation and maintenance manual
serves to help you become familiar with the
http://www.mann-hummel.com/
PreLine and its intended use.
E-mail: if.info@mann-hummel.com
The installation and maintenance manual
contains important information on operating
Contents the components safely, properly and
1 Foreword .............................................................. 2 economically. Observation of the manual
2 Safety.................................................................... 3 helps avoid potential risks, reduce repair costs
2.1 Warning labels and symbols ......................... 3 and downtimes as well as improve machine
2.2 General information ....................................... 3 reliability and increase its service life.
2.3 Intended use .................................................. 3
3 Function Description .......................................... 4 The manual must be available to every person
3.1 PreLine systems for diesel generators from charged with working on the filter.
15 - 250 kW ............................................................... 5 The respective existing national environmental
3.2 PreLine systems for diesel generators from
200 - 600 kW ............................................................. 6
protection regulations (especially on the
3.3 PreLine systems 271, 421 and 601 ............... 7 disposal of removed parts), the general
4 Assembly ............................................................. 8 accident prevention regulations and the other
4.1 General information ....................................... 8 generally recognised safety-related and
4.2 Requirements for installation location ........... 8 industrial safety and health rules must be
4.3 Assembling the PreLine................................. 9
5 Maintenance ......................................................15
complied with.
5.1 Maintenance plan ........................................15 We reserve the right to make technical
5.2 Draining water from filters with integrated modifications to the filter and/or alter the
water collection space .............................................16 content of this installation and maintenance
5.3 Changing the filter for filters with integrated
water collection space .............................................17 manual without notification.
5.4 Draining water from filters with an external
water collecting tank ................................................18
5.5 Changing the water collecting tank .............19
5.6 Changing filters of filters with an external
water collecting tank ................................................20
MANN+HUMMEL Industrial Filters 2

MANN+HUMMEL PreLine
Information for the operator: • Only complete work for which you have
The operator is responsible for the provision of been trained and received the necessary
working equipment complying with basic instruction.
health and safety requirements in accordance • All the filter components, particularly the
with the Ordinance on Industrial Safety and plastic parts, must be covered in the event
Health. This also includes deploying the work of any painting work.
equipment such that it is only used within the
scope of its intended use. The operator can 2.3 Intended use
define individual maintenance and service The PreLine has been exclusively designed
plans and intervals in addition to those for the mechanical filtration of diesel fuel in
stipulated in the installation and maintenance accordance with DIN 590. Any other use
manual. above or beyond this is considered
unintended use. The manufacturer/supplier is
2 Safety
not considered liable for damage resulting
2.1 Warning labels and symbols from unintended use.
Intended use also includes observing the
This symbol appears in all the information in the installation and maintenance
sections of the manual in which your manual and meeting all the inspection and
safety could be at risk. Failure to maintenance conditions.
observe the information provided The operator is obliged to inspect the PreLine
could put persons at risk. once a week for visible signs of external
This symbol appears in all the damage and defects as well as immediately
sections of the manual in which the reporting any changes (including operating
information provided must be strictly behaviour) which may impair functional safety.
observed to prevent damage to or All labels and identifications on the PreLine
destruction of system parts. must be kept in a legible condition.
This symbol appears in all the The filter may only be maintained by
sections of the manual in which the appropriately trained, authorised personnel.
information provided must be The PreLine has been constructed according
carefully observed to ensure trouble- to state-of-the-art technology and accepted
free, economic operation. safety-related regulations. However, the
functional safety of connected equipment can
2.2 General information
be at risk when:
Read the EU Material Safety Data Sheet on
• the PreLine is used improperly,
diesel fuel and observe the information
contained in it regarding handling diesel fuel. • the operating conditions have changed,
• Diesel fuel and fuel fumes are damaging to • reconstructions have been made without
health. prior consultation with the manufacturer,
• Do not inhale them, let them get in your • the necessary maintenance and repair work
eyes or come into direct contact with bare has been neglected.
skin. Only use the PreLine when it is in a technically
• Only complete assembly work when the safe working condition and for its intended use
engine has stopped. taking the relevant technical design, safety
and risk aspects into account and observing
• Relieve pressurised lines before starting the information in the installation and
any work. maintenance manual! Investigate faults (or
• In the case of escaping fuel, place a have them investigated) immediately,
collecting vessel in the appropriate position particularly those which could impair safety!
to prevent environmental pollution.

MANN+HUMMEL PreLine
3 Function Description
The PreLine filter system is designed for use in Options

all diesel engines up to a maximum fuel line • Heater: The fuel flowing through is heated
pressure of 4 bar. It is normally installed in the to prevent the formation of paraffin crystals.
area of the low pressure circuit between the Electronic heaters or heaters with bimetallic
fuel tank and fuel feed pump. At this point, its switches can be used.
multi-layer construction filters out water and
fine particles from the diesel fuel flowing • Fill level sensor: The fill level sensor
through. serves to monitor the fill level of the water.
The fill level is determined by the
Depending on the design of an engine's filter
conductivity of the water.
system, an additional main filter is normally
installed downstream from this prefilter. Connection holes in the filter head which are
not used must be plugged.
The separated water is collected either in the
integrated water collection space or in a
collection tank under the filter, depending on
the filter type, and is drained either via the drain
plug or the water level sensor, if available.

MANN+HUMMEL PreLine
3.1 PreLine systems for diesel generators from 15 - 250 kW

PreLine filter systems in the following sizes are Main features:
available for diesel generators of approx. 15 to
• Best possible filtration with little installation
approx. 250 kW with little installation space:
space
PreLine 50
• 2-hole flange for fixation in confined
PreLine 50/1 installation space
PreLine 50/2
• Water collection space integrated in the
PreLine 150 filter
PreLine 150/1
• Hand pump arranged at 45°
PreLine 100/2
PreLine 250 • Diesel heater (optional)
PreLine 250/1 • Diesel heater bracket, selectable on left or
right
• PreLine 50/2 and 100/2 can be used as
combined prefilter and main filter.
1
1 3
4
4
2 6
7
3
5 14
8 8
10
PreLine 50 9 PreLine 250

15
16
Fig. 1 PreLine 50 and 250
Pos. Name Pos. Name
1 Filter head with flange 7 Outlet (option)
2 Bleed plug 8 MANN-FILTER (quick change filter)
Water level sensor (M8 x 1.25) with integrated
3 Diesel heater (12V or 24V version option) 9
drain plug (PL50 – PL150)
Water level sensor (M12 x 1.5) with integrated
4 Hand pump 10
drain plug (PL250)
5 Outlet (filtered side) 14 Cover cap (transport protection)
Inlet (pre-filtration side), optionally on the
6 15 Water drain plug M8 x 1.25
opposite side
16 Water drain plug M12 x 1.5

MANN+HUMMEL PreLine
3.2 PreLine systems for diesel generators from 200 - 600 kW

PreLine filter systems of the following sizes are Main features:
available for diesel generators from 200 to 600
• 4-hole flange for fixation in vehicles with
kW which require a high performance filtration:
high vibration loads
PreLine 270
• External water collecting tank
PreLine 270/1
PreLine 420 • Hand pump arranged at 45° (option)
PreLine 420/1 • Diesel heater (option)
PreLine 600 • Diesel heater bracket, right
• Only for use as a prefilter
1
4 2
1 4
2 6
7
5
6
5 3
8
8
11
12 11
PreLine 270 PreLine 420
13
Fig. 2 PreLine 270 and 420
Pos. Name Pos. Name

1 Filter head with flange 7 Outlet (option)
2 Bleed plug 8 MANN-FILTER (quick change filter)
3 Diesel heater (12V or 24V version option) 11 Water collecting tank (bowl)
4 Hand pump, cover (option) 12 Fill level sensor (option)
5 Outlet (filtered side) 13 Water drain plug
6 Inlet (pre-filtration side)

MANN+HUMMEL PreLine
3.3 PreLine systems 271, 421 and 601

The following PreLine filter systems are also Main features:
available for diesel generators for 200, 420 and
• 4-hole flange for fixation in vehicles with
600 kW which require a high performance
high vibration loads
filtration:
PreLine 271 • Water collection space integrated in the
filter
PreLine 421
PreLine 601 • Hand pump arranged at 45° (option)
• Diesel heater (option), electronic or with
bimetallic regulation
• Diesel heater bracket, right
• Only for use as a prefilter
4
2
1
6
5
8 7 3
17
18
Fig. 3 PreLine 421
Pos. Name Pos. Name

1 Filter head with flange 6 Inlet (pre-filtration side)
2 Bleed plug 7 Outlet (option)
3 Diesel heater (12V or 24V version option) 8 MANN-FILTER (quick change filter)
4 Hand pump 17 Water level sensor with connection plug
5 Outlet (filtered side) 18 Water drain plug

MANN+HUMMEL PreLine
4 Assembly
4.1 General information 4.2 Requirements for installation

Check that the scope of delivery is complete location
and that there are no signs of damage. • Easily accessible for maintenance.
If parts delivered are damaged, please inform • In direction of flow, downstream from the
MANN+HUMMEL immediately. tank and upstream from the engine
injection nozzle.
Assembly of the PreLine filter system • Not in an area where it could be hit by a
and installation of the lines, stone.
particularly with regard to the
electrical connections, may only be • On the frame, if possible.
carried out by properly trained • Pay attention to the cable length in the
personnel who have received the case of versions with heater and/or fill
necessary instruction. level sensor.
It is essential to observe the • Low-vibration area.
information on correct assembly
• Install the PreLine filter system suspended
when completing assembly and
vertically.
installation work.
• Assemble it above the level of the tank to
Escaping diesel fuel represents a prevent the tank running dry during
health hazard! Wear protective maintenance work on the filter.
goggles and gloves.
(Also refer to the material safety data • To ensure the PreLine filter system
sheet for diesel fuel ) functions safely, the suction height
between the fuel tank and filter head must
When working on the engine / not exceed 1.5 m.
vehicle, do not use the filter as a
climbing aid.
When working on the fuel supply, fuel
tank or lines, always place collecting
vessels underneath in order to collect
any escaping fuel. Dispose of
collected fuel and water according to
the applicable local waste disposal
directives.
Selection of the point of installation is
of considerable importance with
regard to a long-term, effective
function of the filter.
Pay attention to the direction of flow.
Complete fixations and electrical
connections carefully and properly.
Check the filter is fixed properly in the
filter head to ensure reliable
operation.

MANN+HUMMEL PreLine
Prefilters Main filters

PreLine 50 MANN+HUMMEL main filter
PreLine 50/1 MANN+HUMMEL main filter
Not applicable PreLine 50/2 * * The prefilters also fulfil the
function of the main filter here
Not applicable PreLine 100/2*
Suction side Pressure side

ENGINE
Fuel prefilter Feed pump Main fuel filter Injection pump
Water and coarse particles are separated in the prefilters.

FUEL TANK The main filters serve for the additional removal of fine particles from the fuel.
In the case of very high feed volumes and constructional requirements, prefilters can also be
installed on the pressure side. As a result, however, the feed pump is not protected by the filter
system.
Fig. 4 Connection diagram
4.3 Assembling the PreLine
PreLine 50 to 250
Due to the space necessary, the entire filter
system must be taken into account when
selecting the installation location (head with
hand pump, filter with water level sensor and/or
water drain plug and Diesel heater, if
applicable).
Check the delivery is complete.
• Select a suitable point on the vehicle frame

(observe the information in Chapter 4.2). 6
• Locate the hole spacing (if holes are already 7
available) or drill the necessary holes 5
(observe slot spacing, Fig. 5.)
• Fix the filter head to the frame (Ma = 40 +/- 5
Nm) with two screws (M 10 - 8.8) and
washers (10.5 - ISO 7090). Fig. 5 Slot spacing 43 – 79 mm
• Remove the transport plugs.

MANN+HUMMEL PreLine
• Remove the covering caps (transport 6b

protection) from the inlet (Pos. 6, Fig. 5) and
outlet (Pos. 5, Fig. 5).
3
The outlet can be connected at
Pos. 5 or Pos. 7 as required. In this
case, screw the locking screw
M16x1.5 in the respective facing
connection (Ma = 20 ± 4 Nm).
The inlet, together with the adaptor,
can be connected at Pos. 6 or Pos.
6b as required.
The cover or optional diesel heater
(Pos. 3) must be inserted on the
respective facing side.
• Disconnect the fuel line and mount suitable
threaded connections.
• Connect the fuel lines at the inlet (Pos. 6 or
6b, Fig. 5) and outlet (Pos. 5 or 7 Fig. 5). 10
• Check that the water drain plug (option)
(Pos. 16, Fig. 1) is closed (also refer to Fig.
13); close it, if necessary. Fig. 6 Heater and fill level sensor
• Check the filter does not leak.
• Check that the entire filter is firmly fixed
(low-vibration).
• Connect the heater (Pos. 3) and fill level
sensor (Pos. 10) (options).
Pay attention to the instructions

enclosed in the heater packaging
with regard to the heater installation.
If the filter is also to be used as the main fuel

filter, the filter must be installed on the pressure
side of the fuel feed pump (only PreLine 50/2
and PreLine 100/2).

MANN+HUMMEL PreLine
In the case of filter models with a filter capacity

(nominal volume flow rate) of 50 l/h to 150 l/h,
the sensor (Pos. 9) must be connected to the 10
9
chassis ground.
In the case of filter models with a nominal
volume flow rate of 250 l/h, the short circuit to
ground connection of the sensors (Pos. 10) is
achieved via the connection plug.
• Screw the bleed plug a/f 6 (Pos. 2, Fig. 8)
open.
• Operate the hand pump (Pos. 4, Fig. 8) to
draw fuel.
• Continue to pump until no more air escapes
from the bleed plug.
Fig. 7 Water level sensor
• Screw the bleed plug shut
(Ma = 6.5 ±1.3 Nm).
2
• Start the engine. 4
• Check the sealing quality.
Fig. 8 Bleed plug

MANN+HUMMEL PreLine
PreLine 270 to 600

Take the complete filter system (head with
hand pump, filter with bowl and water drain
plug) into account when selecting the
installation point due to the space necessary.

(Pos. a, Fig. 10) (observe the information in
Chapter 4.1).
• Locate the hole spacing (if holes are already
available) or drill the necessary holes (Fig.
9).
• Fix the mounting flange (Pos. 1, Fig. 10) to
the frame (Pos. a, Fig. 10) with two screws
(Pos. b, Fig. 10; M 12 - 8.8) and washers
(12.5 – ISO 7090)
(Ma = 60 ±5 Nm).
In the case of vehicles with high
oscillation/vibration loads, screw the Fig. 9 Slot spacing 50 – 87 mm
flange with two additional screws
(M10-8.8) and washers (10.5-ISO
7090) at the bottom (Ma = 40 ±5Nm).
• Before installation with the 4 screws,
disassemble the filter carefully from the filter
head with a strap wrench to enable easier 2 a b
access to the lower fixation holes. 1
• Remove the covering caps from the inlet c 6
(Pos. 6, Fig. 10) and outlet (Pos. 5, Fig. 10).
The outlet can also be connected at
Pos. 7. To do this, unscrew the a/f 5
sealing plugs from Pos. 7 and screw
them in the outlet Pos. 5 (Ma = 25 ± d 5
5 Nm).
• Disconnect the fuel line and mount the
• Connect the fuel lines (Pos. c and d, Fig.
10) at the inlet (Pos. 6, Fig. 10, thread M16
x 1.5) and outlet (Pos. 5 or 9, Fig. 10, thread
M16 x 1.5).
4
• Ensure that the water drain plug is closed 7
(also refer to Fig. 17).
Fig. 10 Assembly
• Check that the filter and water collecting
tank are tightly sealed.
*Option M16 x 1.5, Ma = 20 ± 4, a/f 22

MANN+HUMMEL PreLine
• Check that the entire filter is firmly fixed • Screw the bleed plug shut
(low-vibration). (Ma = 6.5 ±1.3 Nm).
• Connect the heater and fill level sensor In the case of versions without a
(options) in accordance with the filter order hand pump, vent the system
drawing. according to the vehicle
manufacturer's instructions.
Pay attention to the instructions
enclosed in the heater packaging • Start the engine.
with regard to the heater
installation. • Check the sealing quality.

open.
draw fuel.

MANN+HUMMEL PreLine
PreLine 271, 421 and 601

Take the complete filter system (head with
hand pump, filter with water sensor and
integrated water drain plug) into account when
selecting the installation location due to the
space necessary.

(Pos. a, Fig. 12) (observe the information in
Chapter 4.1).
• Locate the hole spacing (if holes are
already available) or drill the necessary
holes (Fig. 11).
• Fix the mounting flange (Pos.1, Fig. 12) to
the frame (Pos.10, Fig. 12) with two screws
(Pos. b, Fig. 12; M 12 - 8.8) and washers
(12.5 - ISO 7090) (Ma = 60 ±5 Nm).
In the case of vehicles with high
oscillation/vibration loads, screw the Fig. 11 Slot spacing 50 – 87 mm
flange with two additional screws
(M10-8.8) and washers (12.5-ISO
7090) at the bottom (Ma = 40
±5Nm).
• Before installation with the 4 screws,
disassemble the filter carefully from the filter 2 a b
head with a strap wrench to enable easier 1
access to the lower fixation holes. c 6
• Remove the covering caps from the inlet
(Pos. 6, Fig. 12) and outlet (Pos. 5, Fig. 12).
The outlet can also be connected at
Pos. 7. To do this, unscrew the a/f
22 sealing plugs from Pos. 7 and d 5
screw them in the outlet Pos. 5 (Ma
= 20 ± 4 Nm).
• Disconnect the fuel line and mount the
• Connect the fuel lines (Pos. c and d, Fig.
12) at the inlet (Pos. 6, Fig. 12, thread M16*
x 1.5) and the outlet (Pos. 5 or 7, Fig. 12,
thread M16* x 1.5). 4
7
• Check that the water drain plug and water
Fig. 12 Assembly
sensor are closed (also refer to Fig. 17).
*Optional M18 x 1.5, Ma = 25 ± 4, a/f 22

MANN+HUMMEL PreLine
• Check the filter does not leak. • Screw the bleed plug closed in accordance
• Check that the entire filter is firmly fixed
with the information on the quotation
(low-vibration) to the vehicle. drawing
- (Ma = 6.5 ±1.3 Nm, sealing shims,
• Connect the heater and fill level sensor if necessary. DIN 7603 (Ø8.2x11.4x1)
(options) in accordance with the filter order replace aluminium).
drawing. - (Ma = 2.5 ±0.5 Nm, seal models with O-
Pay attention to the instructions ring)
enclosed in the heater packaging
with regard to the heater In the case of versions without a
installation. hand pump, vent the system
according to the vehicle
manufacturer's instructions.
open.
• Operate the hand pump (Pos. 4, Fig. 12) to • Start the engine.
draw fuel. • Check the sealing quality.
No auxiliary tools of any kind may
be used when operating the hand
pump. The pump may only be
operated by the ball of the hand.
5 Maintenance
Do not disassemble the hand pump!
It is not intended that maintenance

on the PreLine filter system is
completed by the driver or workshop
personnel.
5.1 Maintenance plan

Activity Interval Comment
- When necessary or according to the
signal from the fill level sensor
Drain water (if installed) Refer to Chapter 5.2.
- Before it freezes
Together with the main fuel filter Refer to Chapter or quick change filter
Change the quick change filter
- When the engine power output drops label

MANN+HUMMEL PreLine
5.2 Draining water from filters with integrated water collection space
PreLine 50 to 250 and 421, 271, 601

The water collected must be drained off when
the water level sensor issues a corresponding
signal or after the interval stipulated in the
operating manual of the engine manufacturer
or when the quick change filter is changed.
Risk of freezing. Drain off the water

before there is a risk of it freezing.
• Switch off the engine to prevent air getting
into the fuel system.
Place a collecting vessel under the

filter before starting work on it and 9
dispose of any escaping fuel and/or
water collected in accordance with e
the locally applicable environmental
regulations.
open close
• Disconnect the connection cable from the
plug connection (Pos. e) on the water level
sensor. Fig. 13 Draining water PreLine 50 - 250
• Screw open the drain plug or water level

sensor (Pos. 9, Fig. 13 and Pos. 17, Fig 14)
(max. 2 revolutions) and let the water drain
off.
• Assist draining by actuating the hand pump.
• Close the drain plug or water level sensor
again (Ma = 1.6 +/- 0.3 Nm).
• Connect the connection cable to the plug
connection (Pos. e) again.
17
Fig. 14 Draining water, PreLine 421, 271, 601

MANN+HUMMEL PreLine
5.3 Changing the filter for filters with integrated water collection space
Before disassembling the old quick
change filter, unpack the new filter 2 4
and check that it is complete and
shows no signs of transport damage.
Only install undamaged quick
change filters.
filter before starting work on it and
dispose of any fuel collected
according to the applicable
regulations.
• Switch off the engine.
• Place a collecting vessel underneath and
drain off the fuel.
• Screw on the bleed plug (Pos. 2) when the
filter system on the filter head should be
vented or bleed the fuel system at the point
stipulated by the engine supplier.
• Disassemble the water sensor (Pos. 9) from 9
the older quick change filter.
• Disassemble the old quick change filter.
The old quick change filter may be stuck to
the filter head. Loosen it using an
Fig. 15 Bleeding the filter
appropriate tool.
• Screw the water sensor to the new filter. 2
(Tightening torque 1.6 ±0.3 Nm).
• Dispose of the old filter according to the
locally applicable regulations.
• Lightly lubricate the seal on the new quick
change filter with a few drops of oil.
• Screw the filter on by hand until the seal
makes contact.
• Turn further by hand until the filter is firmly
fixed (approx. 3/4 revolution).
• Reconnect the plug connection to the
connection cable.
• Operate the hand pump (Pos. 4) (without 4
any auxiliary tools) to draw fuel.
from the bleed plug. Fig. 16 Bleeding the filter
• Unscrew the bleed plug (Pos. 2, ).
(Tightening torque 6.5 ±1.3 Nm).

MANN+HUMMEL PreLine

change filter, unpack the new filter
change filters.

change filters.
• Start the engine.
5.4 Draining water from filters with an external water collecting tank
PreLine 270 to 600

The water collected must be drained off when
the water collecting tank is full or the quick
change filter must be changed.
Risk of freezing. Drain off the water
before there is a risk of it freezing.
• Switch off the engine to prevent air getting

into the fuel system.
• Connect the hose to the outlet opening
(Pos. e, Fig. 17).
filter before starting work on it and 13
dispose of any escaping fuel and/or
water collected in accordance with 11 e
the locally applicable environmental
regulations. open close
• Unscrew the drain plug (Pos. 13, Fig. 17) at

the bottom of the water collecting tank (Pos. Fig. 17 Draining water
11, Fig. 17) and let the water drain out.
• Screw the drain plug (Pos. 13, Fig. 17) shut
again.

MANN+HUMMEL PreLine
5.5 Changing the water collecting tank

Enclosed in the PreLine filter system package
supplied is a special wrench used to loosen
and retighten the tank.
• Drain the water from the water collecting
tank (refer to Chapter 5.4).
regulations.
• Disassemble the tank (Pos. 11, Fig. 17) g
using the assembly tools inside the
packaging of the new tank.
When doing so, hold the quick
change filter so that it does not
detach from the filter head. 11
• Dispose of the tank according to the locally Fig. 18 Changing the water collecting tank
applicable regulations.
• Lubricate the seal (Pos. g, Fig. 18) on the
new water collecting tank with a few drops
of oil.
• Open the water collecting tank plug by
hand.
• Fit the special wrench to the torque wrench,
and tighten the water collecting tank at 20
Nm.
• Ensure that the water drain plug is closed
(also refer to Fig. 17).
After changing the water tank, the
filter must be vented.
(Refer to Fig. 19)

MANN+HUMMEL PreLine
5.6 Changing filters of filters with an external water collecting tank

change filters.

regulations.
• Place a collecting vessel underneath and
drain off the fuel.
• Disassemble the old quick change filter.
The old quick change filter may be stuck to
the filter head. Loosen it using an
appropriate tool.
• If the water collecting tank is to be reused,
2
screw it off (refer to Chapter 5.5) and check
for signs of damage. Lubricate the new O-
ring (enclosed with the new quick change
filter) lightly with a few drops of oil (Pos. g,
Fig. 18).
• Screw the water collecting tank on the new
filter (refer to Chapter 5.5)
• Dispose of the old filter according to the
locally applicable regulations.
• Lightly lubricate the seal on the new quick
change filter with a few drops of oil.
• Screw the filter on by hand until the seal
makes contact. 4
• Turn further by hand until the filter is firmly
fixed (approx. 3/4 revolution).
• Screw the bleed plug (Pos. 2, Fig. 19) open.
Fig. 19 Bleeding the filter
draw fuel.
• Close the bleed plug.
Bleed the filter, too, after working on
the fuel line!

MANN+HUMMEL PreLine
In the case of versions without a hand

pump, vent the system according to
the vehicle manufacturer's
instructions.
5.7 Troubleshooting
Fault Possible cause Solution
Deficient engine power Filter capacity exhausted Change the filter
Filter inlet/outlet incorrectly
No flow through after assembling the Connect the filter inlet/outlet correctly for the
connected
PreLine filter system (no diesel fuel in function (refer to Ch. 4.3)
the water tank) Leaks in the hose connections
Check the sealed points
or seals
Drain plug open Close drain plug
Air in the fuel system
Leaks in the hose connections Bleed system
(foam formation by fuel feed pump)
or seals Clear any leaks, bleed system

MANN+HUMMEL PreLine
6 Technical Data
6.1 PreLine 50
Primary separation rate in compliance with ISO
19438:2003 PreLine PreLine
PreLine 50
50/1 50/2
Classes 4 µm (c ) 6 µm (c )
Filter medium
Multigrade F_PFO ≥ 10% ≥ 30% X
Multigrade F_PF ≥ 40% ≥ 70% X
Multigrade HE ≥ 95% ≥ 99.5% X
Nominal volume flow rate 50 l/h
Prefiltering function with water separation X X X
Application
Additional main filter function - - X
Not
Water separation recommended
On suction side of fuel feed pump >93%
complying with ISO/TR for use on
16332 suction side
On pressure side of fuel feed pump >93% >93%
Maximum volume of
≈ 80 ml
water collection space
Operating pressure Filter head and quick change filter 4 bar

Right and left, each 2 x M16x1.5
Inlet, pre-filtration side fixed hand pump.
Filter head Connections
Bracket for diesel heater, optionally on right
Outlet, filtered side or left.
Permanently stable when using:
Filter head
Fuel compatibility Fossil fuels - DIN ISO 590
- DIN 51 628
Quick change filter - Kerosene JET-A1

MANN+HUMMEL PreLine
6.2 PreLine 150 and 100

Primary separation rate in compliance with ISO
19438:2003 PreLine PreLine
PreLine 100/2
150 150/1
Classes 4 µm (c ) 6 µm (c )
Filter medium
Multigrade HE ≥ 95% ≥ 99.5% X
Nominal volume flow
150 l/h 100 l/h
rate
Application
Additional main filter function - - X
Not
recommended for
On suction side of fuel feed pump >93%
Water separation use on suction
complying with ISO/TR side
16332
On pressure side of fuel feed pump >93% >93%
Maximum volume of
≈ 80 ml
Inlet, pre-filtration side Right and left, each 2 x M16x1.5

fixed hand pump.
Bracket for diesel heater, optionally on
Outlet, filtered side
right or left.
Filter head Permanently stable hen using:

- DIN ISO 590
Fuel compatibility Fossil fuels
- DIN 51 628
Quick change filter - Kerosene JET-A1

MANN+HUMMEL PreLine
6.3 PreLine 250

Primary separation rate in compliance with
ISO 19438:2003 PreLine 250 PreLine 250/1
Filter medium Classes 4 µm (c ) 6 µm (c )
Prefiltering function with water separation X X
Application
Additional main filter function - -
Water separation On suction side of fuel feed pump >93%
complying with ISO/TR
16332 On pressure side of fuel feed pump >93%
Maximum volume of
≈ 200 ml
Inlet, pre-filtration side Right and left, each 2 x M16x1.5

fixed hand pump.
Bracket for diesel heater, optionally on
Outlet, filtered side
right or left.
Filter head Permanently stable hen using:

- DIN ISO 590
Fuel compatibility Fossil fuels
- DIN 51 628
Quick change filter
- Kerosene JET-A1
6.4 PreLine 270

Application
complying with ISO/TR
16332 On pressure side of fuel feed pump >93%
Maximum volume of
≈ 350 ml
Inlet, pre-filtration side Links 1 x M18x1.5
Filter head Connections With or without hand pump.
Outlet, filtered side Bracket for diesel heater, right.
Filter head Permanently stable when using:
Quick change filter - DIN 51 628

MANN+HUMMEL PreLine
6.5 PreLine 420

Application

in compliance with
ISO/TR 16332 On pressure side of fuel feed pump >93%
Maximum volume of
≈ 600 ml
Inlet, pre-filtration Links 1 x M18x1.5
Filter head Connections side With or without hand pump.

6.6 PreLine 421, 601

ISO 19438:2003 PreLine
PreLine 421 PreLine 601/1
421/1
Multigrade F_PF ≥ 40% ≥ 70% X X
Nominal volume flow rate 420 l/h 600 l/h
Application
Additional main filter function - - -
Water separation On suction side of fuel feed pump >93% >93%
complying with
ISO/TR 16332 On pressure side of fuel feed pump >93% >93%
Maximum volume of
≈ 500 ml
Inlet, pre-filtration Left, 1 x M16x1.5
Filter head Connections side With or without hand pump.


MANN+HUMMEL PreLine
7 Spare Parts
7.1 Spare parts list, PreLine 50-250 filter head
Pos. Name Order number

1 Locking screw, bleeding 21 008 05 311
2 Seal for locking screw, bleeding 01 901 01 008
3 Cover (incl. O-ring) 66 606 47 141
4 Self-tapping screw 01 163 06 018
5 O-ring for adapter 23 023 32 141
6 Adapter for line, M16 x 1.5 66 500 47 101
7 Locking screw, inlet/outlet 01 440 16 001
Seal for locking screw
8 01 901 01 016
inlet/outlet

MANN+HUMMEL PreLine
7.2 Spare parts list, PreLine 50, PreLine 150/100
4,5
3,4

Heater (option, incl. seal), DH 12
1
Installation on left and right possible DH 24
2 Seal, heater 23 023 32 141
3 Locking screw, water drain 21 008 05 269
4 Seal for locking screw, water drain 23 009 31 182
5 Sensor M8 x 1.25 59 020 70 730
6 Seal for sensor M8 x 1.25 23 009 31 182
7.3 Spare parts list, PreLine 250

Heater (option, incl. seal) DH 12
1
Installation on left and right possible DH 24
2 Seal, heater 23 023 32 141
3 Locking screw, water drain 21 012 05 341
5 Sensor M12 x 1.25 59 020 70 731
6 Seal for sensor M12 x 1,25 23 012 31 242

MANN+HUMMEL PreLine
7.4 Order number, complete filter

Name Medium Order number, MANN- Water Hand Water Diesel heater
complete filter FILTER level pump collecting with bimetal
quick sensor tank regulation
change 12 Volt 24 Volt
filter
66 401 62 140 Yes
PreLine 50 PFO PL 50
66 401 62 144 -
Integrated
66 401 62 150 Yes in quick DH 12 DH 24
PreLine 50/1 PF PL 50/1 Yes
66 401 62 154 - change (option) (option)
filter
66 401 62 180 Yes
PreLine 50/2 HE PL 50/2
66 401 62 184 -
66 402 62 140 Yes
66 402 62 144 -
Integrated
66 402 62 150 Yes in quick DH 12 DH 24
PreLine 150/1 PF PL 150/1 Yes
66 402 62 154 - change (option) (option)
filter
66 402 62 180 Yes
PreLine 100/2 HE PL 100/2
66 402 62 184 -
66 504 62 140 Yes
PreLine 250 PFO PL 250 Integrated
66 504 62 144 - in quick DH12 DH 24
Yes
66 504 62 150 Yes change (option) (option)
PreLine 250/1 PF PL 250/1 filter
66 504 62 154 -

MANN+HUMMEL PreLine
7.5 Spare parts list, PreLine 270/420/600 filter head including 271/421

1 Locking screw, inlet/outlet M16 x 1.5 01 440 16 001
1 Locking screw, inlet/outlet M18 x 1.5 01 440 18 001
2 Seal for locking screw, inlet/outlet M16 01 901 01 016
2 Seal for locking screw, inlet/outlet M18 01 901 01 018
3 Locking screw, bleeding 21 008 05 271
4 Seal for locking screw, bleeding 01 901 01 008
5 Cover (incl. O-ring) 66 606 47 141
6 Self-tapping screw for cover 01 163 06 018

MANN+HUMMEL PreLine
7.6 Spare parts list, PreLine 270, 420, 600
1,2
4,5

DH 12
1 Heater (option, incl. seal), installation on right
DH 24
2 Seal for diesel heater 23 023 32 141
Service kit suitable for PreLine with water fill
level sensor (transparent plastic water collector 66 606 12 919
with drain plug, incl. seals)
Service kit suitable for PreLine without water fill
3 level sensor (transparent plastic water collector 66 606 12 949
with drain plug, incl. seals)
The sealing ring for the water collector is
Cannot be supplied
identified by an "X" and supplied with each new
individually
element. Example: PreLine 270 X
Fill level sensor without plug, 70 mm long
4 59 020 70 772
(option, cannot be retrofit)
5 Screw for fill level sensor, M8x30 (2x) 01 381 04 016

MANN+HUMMEL PreLine
7.7 Spare parts list, PreLine 271 and 421
1,2
5,6
3,4

DH 12
1 Heater (option, incl. seal), installation on right
DH 24
2 Seal for diesel heater 23 023 32 141
3 Locking screw (water drain M12 x 1.5 incl. seal) 21 012 05 341
5 Fill level sensor M12 x 1.5 10 517 67 S01
6 Seal for sensor M12 x 1.5 23 012 31 242

MANN+HUMMEL PreLine
7.8 Order number, complete filter

Name Medium Order number, MANN- Water Hand Water Diesel heater with
complete filter FILTER level pump collecting bimetal regulation
quick sensor tank
change 12 Volt 24 Volt
filter
66 604 62 261 Yes Yes
66 604 62 263 - -
PreLine 270 PFO PL 270X
66 604 62 265 - Yes
66 604 62 267 Yes - DH 12 DH 24
Yes
66 604 62 251 Yes Yes (option) (option)
66 604 62 253 PL - -
PreLine 270/1 PF
66 604 62 255 270/1X - Yes
66 604 62 257 Yes -
66 606 62 261 Yes Yes
66 606 62 263 - -
PreLine 420 PFO PL 420x
66 606 62 265 - Yes
66 606 62 267 Yes - DH 12 DH 24
Yes
66 606 62 251 Yes Yes (option) (option)
66 606 62 253 PL - -
PreLine 420/1 PF
66 606 62 255 420/1X - Yes
66 606 62 257 Yes -
PreLine 271 PL 271
66 607 62 110 Yes Yes

66 607 62 112 - -
66 607 62 114 - Yes
Integrated
66 607 62 116 Yes - in quick DH12 DH24
66 607 62 100 Yes Yes change (option) (option)
filter
66 607 62 102 - -
PreLine 421/1 PF PL 421/1
66 607 62 104 - Yes
66 607 62 106 Yes -
66 606 62 992 - Yes
DH12 DH 24
PreLine 600 PFO PL 600 Yes
(option) (option)

MANN+HUMMEL PreLine
8 Technical Report
The suitability of the PreLine filter system for use in motor vehicles is explained in the "Technical
Report on a Prefilter for Diesel Fuel No.:375-0001-01-FBTN" issued by the TÜV on 08.08.2001.
9 Related Documents
The following documents must also be observed and applied in addition to this Operating and
Maintenance Manual:
• Technical data in accordance with the order drawing
• Installation and maintenance manual for the heater 19 611 31 012
European norms, harmonisation documents, national norms as well as manufacturer and
customer-specific specifications were applied.

MANN+HUMMEL PreLine
10 Drilling Templates
10.1 2-hole flange (PreLine 50 to 250)
Fig. 20 Drilling template, 2-hole flange

MANN+HUMMEL PreLine
10.2 4-hole flange (PreLine 270, 420, 600 or 271, 421)
Fig. 21 Drilling template, 4-hole flange

MANN+HUMMEL PreLine
MANN+HUMMEL locations
Joint enterprises
MANN+Hummel Industrial Filters

The MANN+HUMMEL Group is an internationally Filters for the international spare parts market are
active business with its company headquarters in sold under the names of internationally renowned
Ludwigsburg (Germany) and employs a staff of customer brand names as well as our own MANN-
over 14,300 people worldwide in more than 40 FILTER brand.
locations. The industrial filter business unit, with its head
The company develops, produces and sells office in Speyer (Germany), has specialised in
innovative technical components and systems fulfilling the particular demands of customers
for the automobile industry and many other involved in off-highway vehicle/device and engine
market sectors. technology, compressed air and vacuum
High quality filtration products for vehicles technology as well as the mechanical engineering
(devices), engines and industrial applications and construction business sectors.
play a key role in our business activities. The MANN+HUMMEL Industrial Filters provides a wide
initial equipment business with the world's range of high performance products concerned
leading vehicle, machine and system with filtration and separation of air, gases and
manufacturers defines the basis for quality and liquids for these and other business sectors.
performance capabilities of the products.
MANN+HUMMEL GMBH, Industrial Filters Business Division

67346 Speyer, Germany, Telephone +49 (62 32) 53-80, Fax +49 (62 32) 53-88 99
E-mail: if.info@mann-hummel.com, Internet: www.mann-hummel.com

Mann+Hummel Preline Prefilters For Diesel Fuel Installation and Maintenance Manual

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MANN+HUMMEL

Installation and Maintenance Manual

19 611 31 018 en 0112 Version 0112

5.7 Troubleshooting ........................................... 21

Industrial Filters Business Division 1 Foreword

MANN+HUMMEL Industrial Filters 2

MANN+HUMMEL Industrial Filters 3

The PreLine filter system is designed for use in Options

MANN+HUMMEL Industrial Filters 4

3.1 PreLine systems for diesel generators from 15 - 250 kW

PreLine 50 9 PreLine 250

MANN+HUMMEL Industrial Filters 5

3.2 PreLine systems for diesel generators from 200 - 600 kW

Fig. 2 PreLine 270 and 420

Pos. Name Pos. Name

MANN+HUMMEL Industrial Filters 6

3.3 PreLine systems 271, 421 and 601

Fig. 3 PreLine 421

Pos. Name Pos. Name

MANN+HUMMEL Industrial Filters 7

4.1 General information 4.2 Requirements for installation

MANN+HUMMEL Industrial Filters 8

Prefilters Main filters

Suction side Pressure side

Fuel prefilter Feed pump Main fuel filter Injection pump

Water and coarse particles are separated in the prefilters.

Fig. 4 Connection diagram

4.3 Assembling the PreLine

• Select a suitable point on the vehicle frame

MANN+HUMMEL Industrial Filters 9

• Remove the covering caps (transport 6b

Pay attention to the instructions

If the filter is also to be used as the main fuel

MANN+HUMMEL Industrial Filters 10

In the case of filter models with a filter capacity

Fig. 8 Bleed plug

MANN+HUMMEL Industrial Filters 11

PreLine 270 to 600

• Select a suitable point on the vehicle frame

MANN+HUMMEL Industrial Filters 12

• Screw the bleed plug a/f 12 (Pos. 2, Fig. 10)

MANN+HUMMEL Industrial Filters 13

PreLine 271, 421 and 601

• Select a suitable point on the vehicle frame

*Optional M18 x 1.5, Ma = 25 ± 4, a/f 22

MANN+HUMMEL Industrial Filters 14

Do not disassemble the hand pump!

It is not intended that maintenance

5.1 Maintenance plan

MANN+HUMMEL Industrial Filters 15

PreLine 50 to 250 and 421, 271, 601

Risk of freezing. Drain off the water

Place a collecting vessel under the

• Screw open the drain plug or water level

Fig. 14 Draining water, PreLine 421, 271, 601

MANN+HUMMEL Industrial Filters 16

MANN+HUMMEL Industrial Filters 17

Before disassembling the old quick

Before disassembling the old quick

PreLine 270 to 600

• Switch off the engine to prevent air getting

• Unscrew the drain plug (Pos. 13, Fig. 17) at

MANN+HUMMEL Industrial Filters 18