Eaton 145406 Installation and operating instructions

©Copyright Eaton Corp., 2006. All rights reserved.
QRV 9100
Installation, Operation
and Maintenance of
Airflex®Quick Release
Valve
Forward this manual to the person responsible
for Installation, Operation and Maintenance of
the product described herein. Without access to
this information, faulty Installation, Operation or
Maintenance may result in personal injury or
equipment damage.
Use Only Genuine Airflex®Replacement Parts.
The Airfiex Division of Eaton Corporation recommends
the use of genuine Airfiex replacement parts. The use of
non-genuine Airflex replacement parts could result in
substandard product performance, and may void your
Eaton warranty. For optimum performance, contact
Airflex:
In the U.S.A. and Canada:[phone]
Outside the U.S.A. & Canada: [phone]
Internet: www.airflex.com
October, 1987
(Revised : November, 2006)
203977
Note: This manual pertains to the AIRFLEX
DIAPHRAGM OPERATED QUICK RELEASE
VAVLE which is identified by its silver housing. If
your valve housing is anodized green, service it
according to manual QRV 9090 or replace the entire
valve with the diaphragm style.

QRV 9100 (PDF FORMAT) 1
AIRFLEX®QUICK RELEASE VALVE
Figure 1 : Quick Release Valve
TABLE 1:
QRV MODEL and KIT NUMBERS
QRV
SIZE
BASIC QRV
MODEL and KIT
NUMBER
QRV OPTIONS and KITS OPTION and KIT
DESIGNATION***
3/8", 1/2" and 3/4" Size 1"
3/8 145406
w/Metal Sleeve DE BD
w/Rubber Sleeve DF
w/Inlet Pipe Thread DG
1/2 145407
w/Metal Sleeve & Muffler** DS BE
w/Rubber Sleeve & Muffler** DR
w/Inlet Pipe Thread & Muffler** DT
3/4 145141
w/Metal Sleeve & Pipe Adapter DL BR
w/Metal Sleeve & 1/4 Pipe Adapter* DM
1” 146506
Diaphragm & End Cap Kit DP DP
Diaphragm, Muffler & End Cap Kit DQ DQ
*1/4 NPT adapter for 3/8 QRV only.
** Mufflers are not factory-assembled to QRV. See Installation section.
*** The option and kit designation letters must be added as a suffix to the basic model number to completely
identify the QRV model or kit. Diaphragm and end cap kit contains a diaphragm, end cap and sealant. Dia-
phragm, muffler and end cap kit contains diaphragm, end cap, muffler and sealant.

QRV 9100 (PDF FORMAT) 2 ©Copyright Eaton Corp. 2006, All Rights reserved.
1.0 INTRODUCTION
Throughout this manual there are a number of
HAZARD WARNINGS that must be read and
adhered to in order to prevent possible personal
injury and/or damage to equipment. Three sig-
nal words “DANGER”, “WARNING” and
“CAUTION” are used to indicate the severity of
a hazard, and are preceded by the safety alert
symbol
Denotes the most serious hazard, and is
used when serious injury or death WILL
result from misuse or failure to follow spe-
cific instructions.
Used when serious injury or death MAY
result from misuse or failure to follow spe-
cific instructions.
Used when injury or product/equipment
damage may result from misuse or failure to
follow specific instructions.
It is the responsibility and duty of all personnel
involved in the installation, operation and main-
tenance of the equipment on which this device
is used to fully understand the:
procedures by which hazards can be avoided.
1.1 Description
The Airflex®QRV is a quick release valve that
facilitates the release of air from a pressurized
chamber i.e., air cylinders, clutches, brakes or
other pneumatic devices. In essence it provides
an exhaust port at the chamber rather than
exhausting through long supply lines and con-
trol components. The function they perform is
especially important in high speed cycling
equipment. They prevent sluggish operation,
overlap and excessive wear. Their importance
in an air control system cannot be overempha-
sized.
QRV’s are available in four sizes for direct con-
nection to 3/8, 1/2, 3/4 and 1 inch pipe. Models
are also available which permit 1/2, 5/8 and 3/4
inch outside diameter tubing connections to the
QRV inlet port.
Exhaust noise from the valve can be reduced
by using a muffler, which threads into the
tapped hole in the end cap.
1.2 How It Works
Figure 2
The Airflex QRV contains a diaphragm
designed to function on a pressure differential.
Air pressure at the valve inlet seats the dia-
phragm on the end cap, closing the exhaust
port. Applied pressure, acting on the outer
unsupported diaphragm area, deflects it and
allows air to flow to the cylinder port. See Fig-
ure 2.
When a pressure drop occurs in the air supply,
the pressure differential lifts the diaphragm from
the exhaust port and seats it on the inlet port.
Air from the pressurized device can now flow
freely to atmosphere through the valve’s
exhaust port.
If the cylinder pressure falls below the inlet
pressure, the pressure differential on the dia-
phragm will close the exhaust port, preventing
further exhaust.

QRV 9100 (PDF FORMAT)
3 ©Copyright Eaton Corp. 2006, All Rights reserved.
1.3 Specifications
Maximum operating pressure:
150 PSI (10.3 Bar)
Minimum sealing pressure:
2 PSI (.14 Bar)
Air quality: Clean and dry to avoid contamina-
tion of housing and diaphragm. Any additives
used in the air supply must be compatible with
valve materials.
Operating temperature range:
-40°F (-40°C) to 120°F (49°C)
Mean life: Over 5 million cycles 75 PSI (5.1
Bar) and 80°F (27°C).
Diaphragm material: Polyurethane
Housing material: Zinc alloy
End cap material: Noryl®
GRAPHIC SYMBOLS:
Figure 3
2.0 INSTALLATION
Before performing any work, read this manual
and study all figures. Assure yourself that you
understand and can do what is required in each
step. Failure to follow these instructions may
affect quick release valve operation and may
result in exposure to personal injury.
Before installing the valve, set and block the
machine or equipment in a secure position;
close the air shutoff valve and exhaust air
from air lines; and disconnect all electrical
power.
2.1 Air Piping
2.1.1 For fastest response time, use an inlet pipe size
equal to or larger than the quick release valve size.
Minimize the length of pipe between the quick
release valve and air control valve. Keep the number
of fittings, bends and other restrictions in the inlet line
to a minimum.
2.1.2 Piping should be free of foreign material such as pipe
thread sealant, metal chips, etc. Pipe and tubing
ends must be reamed after cutting to prevent a
reduction of effective pipe or tube diameter.
Do not allow foreign matter to enter the
quick release valve. Particles of foreign
matter can prevent diaphragm sealing and
cause air leakage.
2.1.3 Refer to 1.3 for air quality, additives and allowable
operating pressures.
Table 2:
PORT SIZES
QRV Size Inlet Cylinder
3/8 3/8 NPT or 1/2 OD Tube 3/8 NPT
1/2 1/2 NPT or 5/8 OD Tube 1/2 NPT
3/4 3/4 NPT or 3/4 OD Tube 3/4 NPT
1 1" OD Tube 1" NPT
Table 3:
FLOW CAPACITY IN SCFM(m3/min)*
QRV Size Inlet to Cylinder Cylinder to
Exhaust
3/8 121 (3.4) 206 (5.8)
1/2 172 (4.9) 256 (7.2)
3/4 287 (8.1) 376 (17.2)
1 Contact Factory
*At 100 PSIG (6.9 Bar) inlet pressure with full pres-
sure drop.

QRV 9100 (PDF FORMAT) 4
©Copyright Eaton Corp. 2006, All Rights reserved.
2.2 Mounting
2.2.1 Screw the cylinder port of the quick release valve into
the female port of the device using a minimum of
pipe thread sealant. Use a wide, flat faced wrench
which will not crimp or damage the valve body. The
quick release valve must be torqued enough to pro-
duce a tight seal, but not more than the value given in
Table 4.
Do not position the quick release valve
exhaust port in the up position or allow for-
eign matter to enter the valve housing. Parti-
cles of foreign matter will enter the exhaust
air stream and/or prevent diaphragm seating.
Either condition could result in personal
injury or damage to equipment.
Position the quick release valve exhaust port
so that the exhaust air stream does not
strike operating personnel. Particles of for-
eign matter picked up by the air stream can
cause personal injury.
Position the quick release valve exhaust port
so that there are no restrictions to the
exhaust air flow. Any restriction will slow
down the valve response time.
2.2.2 If the quick release valve has pipe threads on the
inlet port, make a direct pipe connection. Do not
exceed the tightening torques given in
Table 4.
2.2.3 For quick release valves having tubing connections,
slide the nut and sleeve onto the inlet air tubing and
insert the tubing or pipe adapter into the valve hous-
ing until it bottoms. Slide the sleeve into its seat in the
housing. Tighten the nut sufficiently to produce an air
seal but not more than the value given in Table 4.
2.2.4 If a muffler is to be used, install per the following
instructions.
Loctite® must be used where called for in
the following procedure. Mufflers installed
without Loctite® may work loose during
operation resulting in personal injury.
Note : Quick release valves supplied prior to Sep-
tember, 1989 do not have threaded end caps to
accept the muffler. The end caps on these valves
must be replaced. Refer to the Maintenance sec-
tion in this manual for end cap replacement.
Note : Mufflers are not factory-assembled to the
quick release valves due to possible interference
with the rims of Airfiex clutch elements. When a
quick release valve having a muffler is ordered, a
basic valve is supplied along with a muffler/end
cap/diaphragm kit. If only the muffler is to be
installed, discard the end cap and diaphragm
included in the kit.
2.2.4.1 Thoroughly clean the female threads in the quick
release valve end cap and the male threads on the
muffler.
2.2.4.2 Apply Loctite®#222 (included in the kit) to the
threads on the muffler, using one drop per thread,
and screw the muffler into the end cap. Torque the
muffler to 60 lb.-in. (7 Nm).
2.3 Testing
2.3.1 Apply air pressure to the quick release valve. The
valve and its connections should not leak under pres-
sure. If the valve leaks, refer to the Maintenance sec-
tion in this manual.
2.3.2 Cycle the valve several times to ensure proper oper-
ation. If the valve response time appears sluggish,
check for restrictions in the air supply line.
Table 4:
Maximum Allowable Tightening
Torque
QRV Size Torque
3/8 40 lb. ft. (54 Nm)
1/2
50 lb. ft. (67 Nm)3/4
1

QRV 9100 (PDF FORMAT) 5
©Copyright Eaton Corp. 2006, All Rights reserved.
3.0 MAINTENANCE
Before performing any work, read this manual
and study all figures. Assure yourself that you
understand and can do what is required in
each step. Failure to follow these instructions
may affect quick release valve operation and
may result in personal injury.
Two quick release valve replacement kits are
available for valve rebuilding. An end cap/dia-
phragm kit is available for valves not having
mufflers, and contains an end cap, diaphragm
and tube of Loctite®#222. An end cap/dia-
phragm/muffler kit contains all of the above
along with a muffler. It is advisable to stock at
least one spare quick release valve for each
size used in an installation.
The quick release valve should be periodically
checked for proper functioning. If the valve fails
to seal, it should be inspected internally. Usually
foreign material will be found which has been
carried through the piping. If a valve becomes
ineffective after prolonged service, it can be
restored to good operating condition by rebuild-
ing.
3.1 Valve and Diaphragm Service
Before performing any work on the valve, set
and block the machine or equipment in a
secure position; close the air shutoff valve
and exhaust all air from the air lines; and dis-
connect all electrical power in order to pre-
vent personal injury and/or equipment
damage.
3.1.1 If the quick release valve exhaust port is positioned
downward, it will be difficult to service the diaphragm.
It is recommended that the valve be removed from
the equipment and bench-serviced.
3.1.2 Use a flat faced wrench to unscrew the muffler (if
present) and the end cap. The diaphragm may fall
out of the housing at this time. Discard the end cap,
muffler and diaphragm.
Note : The end caps on quick release valves man-
ufactured prior to September, 1989, have hex-
shaped exhaust ports to accommodate an allen
wrench for end cap removal. Refer to Table 5 for
the appropriate wrench size to remove the end
cap. Discard after removal.
3.1.3 If the diaphragm did not fall out of the housing, gently
pry along its outside diameter, being careful not to
damage the sealing surface on the housing.
3.1.4 Inspect the diaphragm sealing surface in the housing
(shown on figure) If the surface is worn, scratched or
corroded, the entire quick release valve must be
replaced.
Figure 4
Do not attempt to renew the diaphragm seal-
ing surface by sanding or machining.
Machining the surface will increase the dia-
phragm operating gap and cause the valve to
malfunction.
3.1.5 Thoroughly clean the inside of the housing and the
internal threads in the housing.
Table 5:
End Cap Allen Wrench Size
QRV Size Width Across Flats
3/8 1/2”
1/2
3/4”
3/4
1N/A

QRV 9100 (PDF FORMAT) 6 ©Copyright Eaton Corp. 2006, All Rights reserved.
Do not allow foreign matter to enter either
the valve housing or muffler. Particles of for-
eign matter can prevent diaphragm sealing.
3.1.6 Insert a new diaphragm into the housing so it bot-
toms against the inlet port.
Loctite®must be used where called for in the
following procedure. An end cap and/or muf-
fler installed without Loctite®may work
loose during operation resulting in personal
injury or equipment damage.
3.1.7 Remove and discard the protective cap from the
replacement end cap. Apply Loctite®#222 to the
threads of the end cap, using one drop per thread,
and screw the end cap into the housing. Make sure
the diaphragm is located properly in the housing.
Torque the end cap to 60 lb-in. (7Nm).
3.1.8 If there is sufficient swing clearance on the equip-
ment, the muffler (if applicable) may be installed at
this time; otherwise, install the quick release valve
and muffler onto the equipment per the Installation
section of this manual. When installing the muffler, do
not forget to use Loctite®#222 on the muffler threads
and torque to 60 lb.-in. (7Nm).
3.2 Testing
3.2.1 Test by applying air pressure to the valve. The valve
should not leak under pressure. Removing the air
pressure should cause the diaphragm to shift and
allow the air to exhaust through the end cap and
muffler. If the valve does not function properly, repeat
the servicing procedure.
4.0 Ordering Information/Technical
Assistance
4.1 In any correspondence regarding Airflex quick
release valves, always refer to the size and port
configuration and call or write:
Loctite is a registered trademark of Henkle Technolo-
gies.
Noryl is a registered trademark of The General Elec-
tric Company.
Eaton Corporation
Airflex Division
9919 Clinton Road
Cleveland, Ohio 44144
Tel.: [phone]
Fax: [phone]
Internet : www.airflex.eaton.com

Form ML-318
Revised September 3, 1997
EATON PRODUCT WARRANTY
Subject to the conditions stated herein, Eaton
Corporation warrants to the Purchaser that
each new Airflex Product manufactured by
Eaton will be free from failures caused by
defects in material and workmanship, and will
deliver its rated capacity, for a period of twelve
(12) months from the date of shipment to Pur-
chaser, provided such Product is properly
installed, properly maintained, operated under
normal conditions and with competent supervi-
sion. Warranty claims shall, be made in writing
and the part or parts shall, if requested by Air-
flex Division, be returned prepaid to the Airflex
Division for inspection.Upon a determination
that a defect exists, Eaton shall thereupon cor-
rect any defect, at its option either by repairing
any defective part or parts or by making avail-
able at Eaton’s plant a repaired or replacement
part. This warranty does not extend to normal
wear parts or components of the Product, such
as friction material and friction surfaces.
LIMITATION OF WARRANTY
THE FOREGOING WARRANTY IS EXCLUSIVE
AND IN LIEU OF ALL OTHER WARRANTIES
WHETHER WRITTEN, ORAL OR IMPLIED. ANY
IMPLIED WARRANTY OF MERCHANTABILITY
OR FITNESS FOR A PARTICULAR PURPOSE
ARE SPECIFICALLY EXCLUDED.
In no event shall Eaton be liable for special,
incidental or consequential damages. Eaton’s
liability arising out of the supplying of such
Product, or its use, whether in warranty, con-
tract or otherwise, shall in no case exceed the
cost of correcting defects in the Products as
herein provided. Upon expiration of the twelve
(12) month period, all such liability shall termi-
nate. THE FOREGOING SHALL CONSTITUTE
THE SOLE REMEDY OF PURCHASER AND THE
SOLE LIABILITY OF EATON.
Eaton Corporation
Airfiex Division
9919 Clinton Road
Cleveland, Ohio 44144