Manntek DDC Original operating manual

manntek.se
DDC Service instruction
2” hose unit

2 of 10 – Version 170815

3 of 10 – Version 170815
H OSE U NIT 2”
M ATERIAL : A L , B R , SS
P ARTS NEEDED FOR SERVICE : Spare part kit and O-ring kit (see page 4)
Tool: Hexagon wrench No. 2
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.

4 of 10 – Version 170815
M AINTENANCE AND SERVICE INSTRUCTION
Always depressurize 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.
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 EK SPARE PARTS FOR MAINTENANCE .
Spare part kit (S-S2-xx)
O-ring kit (O-S2-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. S207AxxyyB).

5 of 10 – Version 170815
Begin with unscrewing and remove the
lock screw from the swivel ring.
Tool: Hexagon wrench No. 2
Mark the position of the swivel sleeve
against the swivel ring with an Ø8 mm
pin. Unscrew and remove swivel sleeve
from swivel ring.
Tool: Adjustable wrench
Remove the PTFE bushing on top of
the coupling body.
Remove the two shafts for the piston
guide and the two cylinder PTFE
bushing
Turn the driving plate to the position
where the recess ends up under the
rollers.
Tool: Polygrip plier

6 of 10 – Version 170815
Turn back the unit and remove the
driving plate packet from the coupling
body.
Dismount the handle before you
change O-ring.
If necessary change the O-ring (pos.21)
for dust –protection. Use grease on the
new O-ring.
Remove and 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.
Change the three shafts (pos.18),
locking nuts (pos.19) and rollers
(pos.17) to new ones.
Tool: Standard Wrench 8 mm

7 of 10 – Version 170815
Check the rollers for easy rotation.
Change the O-ring (pos.8) on the
driving plate back side. Use grease on
the O-ring.
Make sure that the O-ring doesn’t get
twisted when mounting.
Change the O-ring (pos.6) on the
driving plate front side. Use grease on
the O-ring.
Make sure that the O-ring doesn’t get
twisted when mounting.
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.
Change the PTFE bushings (pos.16) to
new ones.

8 of 10 – Version 170815
Before the coupling body is placed 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.
Place a new PTFE bushing (pos.25).

9 of 10 – Version 170815
Place a new flat seal (pos.29) on the
swivel sleeve. (Not needed when NPT-
thread or flange)
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.
Use Loctite® 243and 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.

10 of 10 – Version 170815
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 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.