Manntek DCC Original operating manual

DCC Service instruction
6” hose unit
manntek.se

2 of 10 - Version 171113

3 of 10 - Version 171113
HOSE UNIT 6”
MATERIAL:SS
PARTS NEEDED FOR SERVICE:Spare part kit and O-ring kit (see page 4)
TYPE OF CONNECTION:Threaded and Flanged couplings have the
same service instruction.
PERFORM A SERVICE:Daily visual inspection
If leaking
According to application service plan
PLEASE NOTE!
Make sure that you are using no grease for cryogenic applications.

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MAINTENANCE AND SERVICE INSTRUCTION
Always depressurise the system and rinse off the parts before beginning any
maintenance work. Use protective goggles.
Use tweezers and wear gloves which are sufficient for cryogenic applications.
Do not touch adjacent parts with unprotected hands. Rinse off the parts once
again before starting the “daily inspection”
DAILY INSPECTION
1. Inspect the coupling surface for cleanliness and corrosion.
2. Inspect the hose unit swivel for free rotation.
3. Inspect the tank- and hose unit for faultlessness and external signs of seizure.
4. Take care that swivel sleeve is screwed on completely and lock screw is available
and secured.
REGULAR SERVICE
Regular service interval is very much depending on local regulations and application
conditions. If nothing else is specified and it is a new application with unknown parameters
we recommend to make a first service after one year and decide then depending on the
inspection result about further intervals.
The service procedure shall be as follows:
1. Exchange sealing and washer.
2. Check the hose unit ball bearing for faultlessness.
3. Replace worn or damaged components. Repair procedures are straightforward and
no special tools are required.
Check the state of the connection surface and verify that it is clean before proceeding with
the connection.
Couple the repaired unit to a serviceable hose or tank unit as appropriate and check for
correct operation of the valve actuating and bayonet locking mechanism. Couple and
uncouple the unit(s) several times.
USE ONLY ORIGINAL MANNTEK SPARE PARTS FOR MAINTENANCE.
Spare part kit (S-MC6-xx)
O-ring kit (O-MC6-06)
xx means the material key according to the product catalogue. You will find it also as the
8th and 9th sign in the serial number (e.g. MC6100Axx).

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Start with unscrewing and remove the lock screw
from the swivel ring.
Tool: Hexagon wrench No. 2
Different handle configurations are available but
most of the described steps are valid for all
configurations.
Deviations are described where applicable.
Mark the position of swivel sleeve against swivel
ring, to find the right position when remounting.
Lock the swivel ring against the hose unit body
with a pin (Ø8 mm).
Unscrew and remove swivel sleeve from swivel
ring.
Tool: Adjustable wrench
If necessary change seal (pos.21) for dust and
condense water protection.
Unscrew and remove the lock screw (pos 23) and
O-ring (pos 78) from the swivel sleeve.
Twist the swivel sleeve, so the balls drop out (Put
a small container underneath to save the balls for
reassembling later)
It could be helpful to remove the handles before,
depending on the handle configuration.
(No need to dismount the swivel ring if there is no
need to change the dust and condense water
protection seal.)
Tool: Hexagon wrench No. 2
Tool for handles:
A
llen key 6mm
Change the seal for dust and condense water -
protection.
Make sure that the open profile of the seal is
towards the thread. See the picture.

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Remove the shaft for piston guide, by applying
pressure to the driving plate package so that it
moves down, until the driving plate package is
released from the rollers.
The ring surface on the top of the
driving plate is a sealing surface. Press
down the piston only, the driving plate
will follow.
Turn the driving plate to the position where the
driving plate heels are coming free from the
rollers. It could be necessary to release the
package from the press force.
Remove the driving plate package from the hose
unit body.
(There are different ways to remove the driving
plate package. If yours is not possible to remove,
ask your sales representative for an updated
instruction)
Tool: Pliers
Dismounting the inner package in order to
change the seal (pos. 8) on the driving plate.
If necessary, replace the inner rollers (pos. 15)
For some configurations you need to remove
the splint and the pin (pos. 5 and 63) to get the
driving plate package out of the body.
Change the seal (pos.8) ) on the driving plate
back side.
Make sure that the seal doesn’t get
scratched when mounting. The open
profile should be in the direction which
is shown in the picture.

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If necessary change the bushings (pos.13) and
the support ring (pos. 9) to new ones.
Change the O-ring (pos.3) on the piston. Make
sure that the O-ring doesn’t get scratched when
mounting.
If necessary change the three shafts (pos.18),
locking nuts (pos.19) and rollers (pos.17) to new
ones.
Check the rollers for easy rotation.

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Before the coupling body is placed on the driving
plate package, make sure that the part where the
upper cam curve ends, shall be placed exactly
over one roll, and the heel on the driving plate
package should be placed under the hole for the
shaft.
Place the coupling body over the driving plate
package. Grab the piston guide and turn the unit
upside down.
(There are different ways to mount the driving
plate package. If yours is not possible like this,
ask your sales representative for an updated
instruction)
Press down and turn the driving plate to the
position where the driving plate heels are placed
under the rollers.
The ring surface on the top of the
driving plate is a sealing surface. Use a
soft material for pressing it down.
Assemble the shaft and two rollers for piston
guide when applying pressure to the driving plate
packet.
Do not apply too much pressure onto
the inner package, only that the shaft
and the rollers are easy to fit.
If you removed the swivel ring, assemble it back
onto the hose unit body.

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Drop the balls into the swivel joint, turn the swivel
sleeve after each ball. Mount the lip seal (pos.24)
carefully into the groove.
Make sure that the seal doesn’t get
scratched when mounting. The open
profile should be in the direction which
is shown in the picture.
Place the swivel sleeve over the coupling body
and screw in the swivel sleeve.
Take care that the markings you made in the
beginning are aligning.
If necessary apply anti seize lube on the threads.
Use Loctite® 243 and screw the lock screw into
the swivel ring without any force! Risk to deform
the ball bearing!
Apply sealing wax on the lock screw to prevent
misuse.
Finally,
make a visual inspection that everything is in it’s
place. Do also a test connection / disconnection
with a tank unit that not has any fluid inside. If the
coupling works alright you are ready to mount the
hose unit on your hose again.
Loctite® is registered trademark of Henkel.

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TEST PROCEDURE
After each service a tightness test of each coupling is mandatory.
The following test parameters are in accordance with EN12266 and EN14432:
Test procedure Test pressure
A
cceptance criteria
Tightness test (liquid
nitrogen) 6 bar +/- 1 bar No visually detectable
leakage for the duration of
the test
Table 1 – Test pressure
Size Cooling down Keeping time
DN 25 5 min 30 s
DN 50 10 min 45 s
DN 65 12 min 60 s
DN 80 15 min 60 s
DN 100 18 min 90 s
DN 150 20 min 120 s
Table 2 – Minimum test duration
TEST PROCEDURE:
Connect the hose unit to the tank unit
At the beginning the couplings shall be cooled down by opening the tank with liquid
nitrogen for the cooling down time specified in Table 2.
Maintain the test pressure for the keeping time specified in Table 2.
Determine the leakage rate.
Disconnect the hose unit and the tank unit.
Maintain a test pressure of 5 bar in the tested unit(s) for the keeping time specified in
Table 2
Determine the leakage rate while depressurizing the Units.
STORAGE
Store coupling in a dry, dust free, dark place, in ambient temperature.
© Copyright 2008 Mann Teknik AB. Mann Teknik AB reserves the right to make changes at any time in
prices, materials, specifications and models and to discontinue models without notice or obligations.