Manntek DDC Original operating manual

DDC Service instruction
6” hose unit
manntek.se

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Quality, Health, Safety and Environment Policy
Our objectives are simple – no accidents, no occupational illness or work related
accidents, no negative environmental impact and optimizing and continuously
improving customer satisfaction wherever we operate.
Mariestad, February 28 2008
Tony Mann
What does this mean?
In our daily work to develop, sell, deliver and maintain our products this means to
act as soon as we recognize a risk for:
Delivery of products with insufficient technical quality
Giving incorrect information
Not complying with laws and regulations concerning our operation
Causing negative environmental impact
Causing occupational illness or accidents
Not be able to keep promises on delivery terms (product and information)
To act, here means to point out the risk and to make sure we take a balanced
decision to prevent what is undesired.
(This policy includes all that is traditionally covered in separate policies for quality,
health, safety and environment)

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H OSE U NIT 6”
M ATERIAL : A L , SS
P ARTS NEEDED FOR SERVICE : Spare part kit and O-ring kit (see p. 4)
P ERFORM A SERVICE : If leaking
Every year
Change of media
P LEASE NOTE !
Make sure that you are using the right type of O-rings and seals for the
media you are using. We are using a standard silicone based grease for
standard media, for special media please contact us.

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M AINTENANCE AND SERVICE INSTRUCTION
Always depressurise the system and rinse off the parts before beginning any
maintenance work. Use protective goggles. Do not handle O-ring seals if the material
appears charred, gummy or sticky.
Use tweezers and wear neoprene or PVC gloves. Do not touch adjacent parts with
unprotected hands. Rinse off the parts once again before starting the “daily inspection”
D AILY INSPECTION
1. Inspect the coupling surface for cleanliness and corrosion.
2. Inspect the O-ring in the house unit connection for serviceability and correct seating in the
grove.
3. Inspect the hose unit swivel for free rotation.
4. Inspect the tank- and hose unit for faultlessness and external signs of seizure.
5. Take care that swivel sleeve is screwed on completely and lock screw is available and
secured
T HREE - MONTH INSPECTION
1. Exterior cleaning of the coupling halves with a neutral cleanser.
2. Careful “daily inspection” of cleaned units.
O NCE A YEAR
1. Exchange sealing and washer at least once a year.
2. Refill the hose unit ball bearing grooves with grease
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.
U SE ONLY ORIGINAL M ANN T EKNIK SPARE PARTS FOR MAINTENANCE .
Spare part kit (S-S6-xx)
O-ring kit (O-S6-yy)
xx and yy means the material key according to the product catalogue. You will find it also as the 6
th
to 9
th
sign in the serial number (e.g. S6110AxxyyB).

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Begin with unscrewing and remove the
lock screw from the swivel ring.
Tool: Hexagon wrench No.3
If the swivel sleeve has an flat sealing
(pos.29), change it to new one. (Not
needed when NPT-thread).
Dismount the handle.
Tool: Allen key 10 mm
Mark the position of swivel sleeve against
swivel ring with an Ø8 mm pin.
Unscrew and remove swivel sleeve from
swivel ring.
Tool: Adjustable wrench
Change the PTFE ring (pos.25) on the top
of the coupling body.

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Remove the two shafts for piston guide, by
applying pressure to the driving plate
packet so that it moves down 2 mm. So
that the driving plate packet is released
from the rollers.
Turn the driving plate to the position where
the recess ends up under the rollers under
pressure to the driving plate packet.
Remove the driving plate packet from the
hose unit body.
Change the three shafts (pos.18) and
rollers (pos.17) to new ones.
Check the rollers for easy rotation.
Tool: Standard wrench 13 mm
Change the PTFE ring (pos.45).

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Change the O-ring (pos.24) from the
groove in the coupling body.
Use grease on the new part. Apply grease
on the balls for best possible swivel
rotation.
A mounting sleeve is recommended to
mount the o-ring. If no sleeve is available a
plastic strip can be taped around the body
to cover the cam curves.
If necessary change O-ring (pos.21) for
dust –protection. Use grease on the new
O-ring.
Change the O-ring (pos.8) and PTFE ring
(pos.9) on the driving plate back side. Use
grease on O-ring.
Make sure that the O-ring doesn’t get
twisted when mounting.
1. Pos.13
2. Pos.9
3. Pos.8
Change the O-ring (pos.3) on the piston.
Use grease on the new O-ring. Make sure
that the O-ring doesn’t get twisted when
mounting.
Press down the O-ring with your thumb.
Make sure that the O-ring fits into the
groove.
2
3
1

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Before the coupling body places on the
driving plate packet, 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 packet should
be placed under the hole for the shaft.
Place the coupling body over the driving
plate packet. Grab the piston guide and
turn the unit upside down.
Press down and turn the driving plate to
the position where the driving plate heels
are placed under the rollers.
Assemble the two shafts for piston guide
when applying pressure to the driving plate
packet.
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.

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Mount back the handle.
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 top of the lock
screw after screwing it in, 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 pressure and tightness test of each coupling is mandatory. If only the O-Ring
kit is replaced a seat tightness test is enough.
The following test parameters are in accordance with EN12266 and EN14432:
Test procedure Test pressure Acceptance criteria
Shell tightness test
(Water)
1,5 x working
pressure No visually detectable
leakage for the duration of
the test
Seat tightness test (Air) 6 bar +/- 1 bar
Max 0,3 bar
Table 1 – Test pressure
Nominal size Minimum test duration
Up to DN 50 15 s
DN 65 to DN 150 60 s
Table 2 – Minimum test duration
T EST P ROCEDURE :
•Fill the downstream valve cavity including, if appropriate, the cover cavity with the test
fluid.
•Apply the test pressure specified in Table 1 in the direction tending to close the
obturator.
•Maintain the test pressure for the test duration specified in Table 2.
•Determine the leakage rate.
If a pressure test should be achieved for the coupling mounted in an assembly follow the
respective test instructions for the equipment but do not exceed 1,5 x Working Pressure of the
coupling.
S TORAGE
Store coupling in a dry, dust free, dark place, in ambient temperature.
© Copyright 2011 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.