TOOL EXCHANGE VALVE
Contents
1. constructed of thermoplastic or synthetic rubber inner tube synthetic fiber braid reinforcement and weather resistant thermoplastic or synthetic rubber cover Hose labeled certified non conductive is the only hose authorized for use near electrical conductors Wire braided conductive constructed of synthetic rubber inner tube single or double wire braid reinforce ment and weather resistant synthetic rubber cover This hose is conductive and must never be used near electrical conductors Fabric braided not certified or labeled non conductive constructed of thermoplastic or synthetic rubber in ner tube synthetic fiber braid reinforcement and weather resistant thermoplastic or synthetic rubber cover This hose is not certified non conductive and must never be used near electrical conductors HOSE SAFETY TAGS To help ensure your safety the following DANGER tags are attached to all hose purchased from Stanley Hydraulic Tools DO NOT REMOVE THESE TAGS If the information on a tag is illegible because of wear or damage replace the tag immediately A new tag may be obtained from your Stanley Distributor THE TAG SHOWN BELOW IS ATTACHED TO CERTIFIED NON CONDUCTIVE HOSE DANGER DANGER 1 FAILURE TO USE HYDRAULIC HOSE LABELED AND CERTIFIED AS NON CONDUCTIVE DO NOT EXCEED HOSE WORKING PRESSURE OR ABUSE HOSE IMPROPER USE WHEN USING HYDRAULIC TOOLS ON OR NEAR ELECTRIC LINES MAY RESULT IN OR HANDLING OF HOSE COULD RESULT IN BURST2. ABRASIONS BULGES OR DAMAGE TO NOT LABELED OR CERTIFIED AS NON CONDUCTIVE USING THIS HOSE ON OR NEAR COUPLINGS IF ANY OF THESE CONDITIONS EXIST REPLACE THE HOSE IMMEDIATELY ELECTRICAL LINES MAY RESULT IN DEATH OR SERIOUS INJURY NEVER USE TAPE OR ANY DEVICE TO ATTEMPT TO MEND THE HOSE FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROPERLY 6 AFTER EACH USE STORE IN A CLEAN DRY AREA TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND ELEC TRIC LINES DO NOT EXCEED HOSE WORKING PRESSURE OR ABUSE HOSE IMPROPER USE OR HANDLING OF HOSE COULD RESULT IN BURST OR OTHER HOSE FAILURE KEEP HOSE AS FAR AWAY AS POSSIBLE FROM BODY AND DO NOT PERMIT DIRECT CONTACT DURING USE CONTACT AT THE BURST CAN CAUSE BODILY INJECTION AND SEVERE PERSONAL INJURY HANDLE AND ROUTE HOSE CAREFULLY TO AVOID KINKING CUTTING OR CONTACT WITH HIGH TEMPERATURE SURFACES DO NOT USE IF KINKED DO NOT USE HOSE TO PULL OR LIFT TOOLS POWER UNITS ETC DO NOT REMOVE THIS TAG 9V1 SIHL dAOW3H LON OG EMEND SEE OTHER SIDE EA EEE e SE Lx SEE OTHER SIDE SIDE 1 SIDE 2 Shown smaller than actual size 6 gt Tool Exchange Valve User Manual STAN LEY HTMA TOOL TYPE HYDRAULIC SYSTEM REQUIREMENTS TYPE I TYPE Il TYPERR TYPE III Flow Range 4 6 gpm 7 9 gpm 9 10 5 gpm 11 13 gpm 15 23 Ipm 26 34 Ipm 34 40 Ipm 42 49 Ipm Nominal Operating Pressure 1500 psi 1500 psi 1500 psi 1500 psi at the power supply out
3. the number listed on the back of this manual and ask for a Customer Service Representative STAN LEY Tool Exchange Valve User Manual 3 Safety symbols and signal words as shown below are used to emphasize all operator maintenance and repair ac tions which if not strictly followed could result in a life threatening situation bodily injury or damage to equipment This is the safety alert symbol It is used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death This safety alert and signal word indicate an imminently hazardous situation DANGER which if not avoided will result in death or serious injury This safety alert and signal word indicate a potentially hazardous situation which if not avoided could result in death or serious injury This safety alert and signal word indicate a potentially hazardous situation which if not avoided could result in death or serious injury This signal word indicates a potentially hazardous situation which if not avoid ed may result in property damage This signal word indicates a situation which if not avoided will result in damage NOTICE to the equipment This signal word indicates a situation which if not avoided may result in dam IMPO RTANT age to the equipment Always observe safety symbols They are included for your safety and for the protection of the tool LOCAL SAFETY REGULATION
4. A Type Il RR uec I EE 4 10 5 gpm 15 40 Ipm Operating Pressure exer eot IARE 2000 psi 140 bar Maximum Relief Pressure 2 2500 psi 170 bar Tool PONG uden a A 8 SAE O Ring EQUIPMENT PROTECTION amp CARE In addition to the Safety Precautions found in this manual observe the following for equipment protection and care e sure all couplers are wiped clean before con nection Always store the valve in a clean dry space safe from damage or pilferage Make sure the circuit PRESSURE hose with male quick disconnect is connected to the IN port The circuit RETURN hose with female quick disconnect is connected to the opposite port Do not reverse cir cuit flow This can cause damage to internal seals Always replace hoses couplings and other parts with replacement parts recommended by Stanley Hydraulic Tools Supply hoses must have a mini mum working pressure rating of 2500 psi 172 bar 10 Tool Exchange Valve User Manual Do not exceed the rated flow see Specifications in this manual for correct flow rate and model number Rapid failure of the internal seals may result Valve repair should be performed by experienced personnel only Make certain that the recommended relief valves are installed in the pressure side of the system Do not use the valve for applications for which it was not int
5. OR OTHER HOSE FAILURE DEATH OR SERIOUS INJURY KEEP HOSE AS FAR AWAY AS POSSIBLE FROM BODY AND DO NOT PERMIT DIRECT CONTACT DURING USE CONTACT AT THE BURST CAN CAUSE BODILY INJECTION AND SEVERE PERSONAL INJURY ELECTRIC LINES HANDLE AND ROUTE HOSE CAREFULLY TO AVOID KINKING ABRASION CUTTING OR CONTACT WITH HIGH TEMPERATURE SURFACES DO NOT USE IF KINKED DO NOT BEFORE USING HYDRAULIC HOSE LABELED AND CERTIFIED AS NON CONDUCTIVE USE HOSE TO PULL OR LIFT TOOLS POWER UNITS ETC ON OR NEAR ELECTRIC LINES WIPE THE ENTIRE LENGTH OF THE HOSE AND FIT CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS BULGES OR DAM TING WITH A CLEAN DRY ABSORBENT CLOTH TO REMOVE DIRT AND MOISTURE AND TEST HOSE FOR MAXIMUM ALLOWABLE CURRENT LEAKAGE IN ACCORDANCE WITH AGETO GOUELINGS IE ANT OF THESE CONDINONSIENST REPLACE THE HOSE IMMEDIATELY NEVER USE TAPE OR ANY DEVICE TO ATTEMPT TO MEND THE HOSE SAFETY DEPARTMENT INSTRUCTIONS AFTER EACH USE STORE IN A CLEAN DRY AREA FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROP ERLY TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND DO NOT REMOVE THIS TAG SIHL 3AOW3H LON OG SEE OTHER SIDE SEE OTHER SIDE SIDE 1 SIDE 2 Shown smaller than actual size THE TAG SHOWN BELOW IS ATTACHED TO CONDUCTIVE HOSE DANGER DANGER DO NOT USE THIS HYDRAULIC HOSE ON OR NEAR ELECTRIC LINES THIS HOSE IS 5 CHECKENTIRE HOSE FOR CUTS CRACKS LEAKS
6. S Enter any local safety regulations here Keep these instructions in an area accessible to the operator and mainte nance personnel 4 gt Tool Exchange Valve User Manual STAN LEY Tool operators and maintenance personnel must always comply with the safety precautions given in this manual and on the stickers and tags attached to the tool and hose These safety precautions are given for your safety Re view them carefully before operating the tool and before performing general maintenance or repairs Supervising personnel should develop additional pre cautions relating to the specific work area and local safety regulations If so place the added precautions in the space provided on the previous page This valve will provide safe and dependable service if operated in accordance with the instructions given in this manual Read and understand this manual and any stickers and tags attached to the tool and hose before operation Failure to do so could result in personal injury or equipment damage operator must start in a work area without by standers Flying debris can cause serious injury Do not operate the valve unless thoroughly trained or under the supervision of an instructor Establish a training program for all operators to ensure safe operation Always wear safety equipment such as goggles ear and head protection and safety shoes at all times when operating the valve Use gloves and aprons when
7. TOOL EXCHANGE VALVE USER MANUAL Safety Operation and Maintenance 2014 Stanley Black amp Decker Inc New Britain CT 06053 U S A 69723 10 2014 Ver 3 SAFETY SYMBOL Sinto ctu 4 SAFETY PREGCAUTIOINGS tert teret e nett eerte tt el ee EE RT da 5 HOSE TYPES sasssnsaass emm 6 REQUIREMENTS ideer nn ensure 7 OPERATION EC 8 SPECIFICATIONS ze een a 10 TOOL EXCHANGE PARTS ILLUSTRATION AND LIST HANDHELD VERSION P N 67005 11 TOOL EXCHANGE PARTS ILLUSTRATION AND LIST RAILROAD VERSION P N 69722 12 IMPORTANT To fill out a Product Warranty Validation form and for information on your warranty visit Stanleyhydraulics com and select the Company tab Warranty NOTE The warranty Validation record must be submitted to validate the warranty SERVICING This manual contains safety operation and routine maintenance instructions Stanley Hydraulic Tools recommends that servicing of hydraulic tools other than routine maintenance must be performed by an authorized and certified dealer Please read the following warning SERIOUS INJURY OR DEATH COULD RESULT FROM THE IMPROPER REPAIR OR SERVICE OF THIS TOOL REPAIRS AND OR SERVICE TO THIS TOOL MUST ONLY BE DONE BY AN AUTHORIZED AND CERTIFIED DEALER For the nearest authorized and certified dealer call Stanley Hydraulic Tools at
8. ended STANLEY TOOL EXCHANGE PARTS ILLUSTRATION AND LIST HANDHELD VERSION P N 67005 STANLEY PART TEM NO QTY DESCRIPTION 1 ADAPTER HOSE WHIP 12 2 COUPLER 3 8 FEMALE 3 8 NPT FL FACE SET 03971 03973 2 COUPLER 3 8 MALE 3 8 NPT FL FACE SET 03974 BACK UP RING N 9 e zx o 9721 INLINE CALVE BODY ASSY Tool Exchange Valve User Manual lt 11 TOOL EXCHANGE PARTS ILLUSTRATION AND LIST RAILROAD VERSION P N 69722 PART ITEM NO QTY DESCRIPTION 12 Tool Exchange Valve User Manual 2 fora ores 47436 2 i 47437 2 CESE s 82714 ra ers O RING BACK UP RING O RING COUPLER 3 8 FEMALE 3 8 NPT FL FACE SET 47438 COUPLER 3 8 MALE 3 8 NPT FL FACE SET 47438 STANLEY STANLEY Stanley Hydraulic Tools 3810 SE Naef Road Milwaukie Oregon 97267 5698 USA 503 659 5660 Fax 503 652 1780 www stanleyhydraulics com
9. expected oil temperature extremes that will be experienced in service determine the most suitable temperature viscosity characteristics Hydraulic fluids with a viscosity index over 140 will meet the requirements over a wide range of operating temperatures SSU Saybolt Seconds Universal EHTMA CLASSIFICATION HYDRAULIC SYSTEM mE A A A A Flow Range 3 5 4 3 gpm 4 7 5 8 gpm 7 1 8 7 gpm 9 5 11 6 gpm 11 8 14 5 gpm 13 5 16 5 Ipm 18 22 Ipm 27 33 Ipm 36 44 Ipm 45 55 Ipm Nominal Operating Pressure 1870 psi 1500 psi 1500 psi 1500 psi 1500 psi at the power supply outlet 129 bar 103 bar 103 bar 103 bar 103 bar System relief valve setting 2495 psi 2000 psi 2000 psi 2000 psi 2000 psi at the power supply outlet 172 bar 138 bar 138 bar 138 bar 138 bar NOTE These are general hydraulic system requirements See tool specification page for tool specific requirements STAN LEY Tool Exchange Valve User Manual 4 7 PRE OPERATION PROCEDURES Ensure that you have read and understand the safety instructions included in this manual before you operate the valve Check whether the valve is damaged Check that all the parts are functioning correctly Check that moving parts do not become stuck and are not damaged DO NOT use the valve if damaged or defective parts are detected Damaged or defective parts must be repaired by a qualified technician Using a calibrated flow meter and pressure gauge check that the hyd
10. let 103 bar 103 bar 103 bar 103 bar System relief valve setting 2100 2250 psi 2100 2250 psi 2200 2300 psi 2100 2250 psi at the power supply outlet 145 155 bar 145 155 bar 152 159 bar 145 155 bar Maximum back pressure 250 psi 250 psi 250 psi 250 psi at tool end of the return hose 17 bar 17 bar 17 bar 17 bar Measured at a max fluid viscosity of 400 ssu 400 ssu 400 ssu 400 ssu at min operating temperature 82 centistokes 82 centistokes 82 centistokes 82 centistokes Temperature Sufficient heat rejection 140 F 140 F 140 F 140 F capacity to limit max fluid temperature to 60 C 60 C 60 C 60 C at max expected ambient temperature Min cooling capacity at a temperature 3 hp 5 hp 6 hp 7 hp difference of between ambient and fluid 2 24 kW 3 73 kW 5 22 kW 4 47 kW temps 40 F 40 F 40 F 40 F NOTE 22 C 22 C 22 C 22 C Do not operate the tool at oil temperatures above 140 F 60 C Operation at higher temperatures can cause operator discomfort at the tool Filter 25 microns 25 microns 25 microns 25 microns Min full flow filtration 30 gpm 30 gpm 30 gpm 30 _ Cm dirt holding capacity Hydraulic fluid Petroleum based 100 400 ssu 100 400 ssu 100 400 ssu 100 400 ssu premium grade anti wear non conductive 20 82 centistokes Viscosity at min and max operating temps NOTE When choosing hydraulic fluid the
11. necessary The operator must be familiar with all prohibited work areas such as excessive slopes and danger ous terrain conditions e M Maintain proper footing and balance at all times Donotinspect or clean the valve while the hydraulic power source is connected Accidental engagement can cause serious injury Do not operate the valve at oil temperatures above 140 F 60 C Operation at higher temperatures can cause higher than normal temperatures at the valve which can result in operator discomfort Do not operate a damaged improperly adjusted or incompletely assembled valve STANLEY Always use accessories that conform to the speci fications given in the OPERATION section of this manual When working near electrical conductors always assume that all conductors are energized and that insulation clothing and hoses can conduct electric ity Use hose labeled and certified as non conduc tive To avoid personal injury or equipment damage all valve repair maintenance and service must only be performed by authorized and properly trained per sonnel Do not carry the valve by hoses Tool Exchange Valve User Manual lt 5 The rated working pressure of the hydraulic hose must be equal to or higher than the relief valve setting on the hy draulic system There are three types of hydraulic hose that meet this requirement and are authorized for use with Stanley Hydraulic Tools They are Certified non conductive
12. raulic power source develops a flow of 4 10 5 gpm 15 40 Ipm at 2000 psi 140 bar with a maxi mum relief pressure not to exceed 2500 psi 170 bar INSTALLATION The Tool Exchange Valve is intended to be installed be tween the tool and the end of the hydraulic hose Connect the Tool Exchange Valve to the hydraulic pow er supply on the side of the valve labeled Power as shown below Observe the flow indicators cast into the valve and stamped on the couplers to ensure that the flow is in the proper direction Connect the Tool Exchange Valve to the tool on the side of the valve labeled Tool as shown below Observe the flow indicators cast into the valve and stamped on the couplers to ensure that the flow is in the proper direction g 4 JE Q 8 Tool Exchange Valve User Manual STANLEY OPERATION The Tool Exchange Valve is intended to function as a momentary ON OFF valve that when plumbed between a tool and a hydraulic power supply will allow the end user to change tools without having to turn off the hy draulic circuit Shifting the Tool Exchange Valve s spool to the ON posi tion will allow the tool to function normally The hydraulic oil will flow from the hydra
13. ulic power supply through the valve to the tool Return oil will flow from the tool through the valve and back to the hydraulic power supply s res ervoir Shifting the Tool Exchange Valve s spool to the OFF po sition will disconnect the tool from the hydraulic power supply This will allow the end user to remove the tool and attach an alternate tool Shifting the Tool Exchange Valve s spool to the ON position will allow the alternate tool to function normally STANLEY With a constant flow open center hydraulic power supply shifting the Tool Exchange Valve s spool to the OFF position will force all the hydraulic flow through the system s relief valve This valve is intended for tool exchange only and should not be left in the OFF position for more than 30 seconds Failure to heed this warning can result in seal failure excessive heat and damage to the tool and hydraulic power supply The Tool Exchange Valve should not be used as a tool ON OFF valve Use Part Number 38632 In Line Valve for those applications STORAGE Replace any damaged or missing safety labels and tags be fore storing the tool Clean dry and lubricate moving parts before storing the tool Store the tool in a clean dry place Tool Exchange Valve User Manual lt 9 Lengi esi c EE 3 000 inches 7 6 cm E 1 500 inches 3 8 cm Height EE I E D LU 3 750 inches 9 5 cm System TYPO HTM
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