HC-2 CONTROLAIR® VALVE

Service Information

Description of Models
The HC-2 Type Controlair Valves are handle
operated 4-way, exhausted center, pressure
control valves.
The typical unit contains two directional control
3-way side valves and a pressure graduating
portion that is arranged to increase, decrease
or maintain air pressure to (2) separate delivery
lines. In neutral position both 3-way side valves
exhaust both delivery lines. A movement of 10
degrees either side of center position opens
the appropriate side valve and directs pressure
to the indicated outlet port. Continued move-
Table of Contents Page ment past 10 degrees up to full travel or 46
degrees either side of neutral continues to ac-
Description of Models 1 tuate the pressure-graduating portion to deliver
Warnings 2 a graduated pressure according to the value of
Technical Data 2 the control spring.
Installation 2
Maintenance and Repair 2
Models
Outline Dimensions 3
Descriptions of Operation 4 There are four models with similar valve func-
Maintenance and Repair 5 tions, but different handle operating character-
Graphical Symbol 6 istics.
Identity Schedule 7 HC-2-X Controlair Valve -Handle is spring
Exploded View 8 returned to neutral position from all positions in
Part List 9 the handle travel. Some special models exist.
Repair Kit List 10 See notes on Identity schedule on page 7.
Testing HC-2-LX Controlair Valve - Handle is spring
Function 11
returned to neutral position from all positions
Pressure Range 11
Leakage 11 except at the maximum pressure setting on
Flow Capacity 11 both sides of center. The handle is held in both
Response 11 extreme positions by a mechanical detent.
Mechanical Detents 11 HC-2-FX Controlair Valve - Handle is
Test Setup 11 equipped with a friction brake that will hold the
Test Diagram 12 handle in any position selected in the handle
travel.
HC-2-SX Controlair Valve - Handle holds in
only one maximum pressure position. The han-
dle is spring returned to neutral position from
all other positions in the handle travel. The
valve can be ordered to hold in either extreme
position.

SM-800.6505
 Installation and General Maintenance Recommendations
WARNING: INSTALLATION AND MOUNTING
The user of these devices must conform to all
applicable electrical, mechanical, piping and
other codes in the installation, operation or re-
pair of these devices.
INSTALLATION! Do not attempt to install,
operate or repair these devices without
proper training in the technique of working
on pneumatic or hydraulic systems and de-
vices, unless under trained supervision.
Compressed air and hydraulic systems con-
tain high levels of stored energy. Do not
attempt to connect, disconnect or repair
these products when a system is under
pressure. Always exhaust or drain the pres-
sure from a system before performing any
service work. Failure to do so can result in
serious personal injury.
MOUNTING! Devices should be mounted
and positioned in such a manner that they
cannot be accidentally operated.
Installation and General Maintenance Rec-
ommendations
Before installing the Controlair® Valve, all air
lines in the system should be cleaned to re-
move all dirt, moisture or contamination.
A strainer is furnished on the inlet port to pro-
tect the valve from large particles or foreign
matter in the supply line. To ensure long, trou-
ble-free service, a 10 micron or better filter
should be installed in the supply line to the
valve.
The HC-2 Controlair Valve is designed for
panel mounting. The valve less the pipe
bracket can be installed from the top of the
panel. Refer to the installation view for panel
opening dimension. Allow suitable clearance
for installing or removing of the (3) pipe bracket
screws which are 2 1/8” (54mm) long.
Page 2
GENERAL MAINTENANCE AND REPAIR
RECOMMENDATIONS
Maintenance periods should be scheduled in accor-
dance with frequency of use and working environment
of the Controlair Valve.
All valves must be visually inspected for wear and
given an “In System” operating performance and leak-
age test at least once a year. If these visual observa-
tions indicate valve repair is required, the valve must
be removed immediately and repaired.
A major overhaul is recommended at one million cy-
cles. However, where frequency of use is such that it
would require more than two years to obtain the one
million cycles, the valve must be overhauled at the two
year period.
When it is determined that the Controlair Valve re-
quires a major repair as a result of the one million cy-
cles, one year routine inspection or the two year ser-
vice period has elapsed, the device must be disassem-
bled, cleaned, inspected, parts replaced as required.
The valve then must be tested for leakage and proper
operation prior to installation, refer to the Major Repair
and Maintenance Instructions and test procedures.
Notice that the operating portion of the valve can be
removed without disturbing the pipe connections by
just removing the (3) screws that hold the pipe bracket
to the valve.
No special tools are required to maintain the Controlair
valves, with the exception of internal snap– ring pliers.
One complete Controlair valve should be kept in stock
for every (4) valves in service. During the maintenance
period, replacing the complete valve with the stand-by
unit reduces production down time and affords inspec-
tion and replacement of parts at a more appropriate
time and favorable location.
Technical Data:
Max. Operating Pressure 200 PSI (13.8 Bar)
Admissible Mediums Clean & Dry Compressed Air
Operating Temperature -40° to 160° F( -40° to 71° C)
Hysteresis 1 1/2 Psi
Control Pressure Range Ref. Identity Chart
Pressure Change 1/2 Psi Increments
Mounting Flanged Plate
Port Size 1/4-18 NPTF
Materials
Controlair Valve
Housing & Body Die Cast Aluminum
Internal Parts Brass, Rubber, Aluminum, Steel,
Plastic and Hytrel™
Weight 9 Lb. (4.1 Kgs.)
 Outline View
HC-2 Controlair® Valve

Page 3
 Description of Operation
For HC-2 Controlair®

Note in the diagrammatic view that supply pressure is connected to

port (2) and this supply pressure is directed only to the pressure-
graduating portion. The delivery from the pressure graduating portion
encounters plugged port (8) (a pressure gage can be connected at
this port) and continues to become the supply air to each of the side
valves. The delivery from the side valves is directed to outlet ports
(1) or (3).
With the handle in neutral position, both outlet ports are exhausted to
atmosphere through their respective side valve.
Movement of the handle through the first 10 degrees of travel from
neutral operates one of the 3 way side valves to connect the gradu-
ated pressure from the graduating portion to the appropriate outlet
port (1) or (3).
Movement of the handle beyond 10 degrees either side of center po-
sition starts the cam to push down on the pressure control plunger
closing the exhaust valve and opening the upper supply valve that
allows air to flow through the selected side valve to an outlet port. As
the pressure builds up in the delivery line, it acts through the sensing
port orifice and deflects the control diaphragm downward, compress-
ing the control spring. When sufficient diaphragm deflection is ob-
tained to allow the upper supply valve in the pressure control portion
to close, the pressure in the delivery line is held to that value.
The value of the pressure delivered to the outlet port is proportional
to the pressure graduating portion plunger movement. This move-
ment in turn is controlled by the cam contour and is proportional to
the handle travel.
The HC-2 Controlair Valve will automatically compensate for air pres-
sures changes. These air pressure changes can be caused by line
leakage, temperature change or load feedback. If air pressure at the
outlet port increases over that called for by the handle position, the
diaphragm in the control portion will deflect downward opening the
lower exhaust valve and exhausting air until the original setting is ob-
tained. If the pressure drops below that called for by the handle posi-
tion, the decreased force on the diaphragm will allow the control
spring to force the diaphragm upward, opening the upper supply
valve to restore the set pressure.
The range of pressure is controlled by the strength of the diaphragm
spring. Various values are available as shown on the Identity Sched-
ule on page 7.

Page 4
 Repair and Maintenance Instructions
Repair and Maintenance Instructions Graduated Output Pressure Adjustments
When it has been determined that the Controlair® Valve Adjusting screw Item #40 varies the maximum pressure
requires repairs, the following general instructions are rec- setting. Turning the adjusting screw in raises the maximum
ommended. pressure. Turning the screw out decreases the maximum
pressure. The maximum control pressure adjustment should
Disassembly, Cleaning and Lubrication not exceed the maximum control pressure shown in the
Completely disassemble the Controlair valve. Wash all Identity Schedule for part numbers. (Control springs are
metal parts in a non-flammable solvent. Rinse each part color-coded).
thoroughly and blow dry with low-pressure air. Changing the control spring Item #30 can change the
Inspect and clean the inlet filter Item #2. Be sure all pas- maximum output pressure rating.
sages in the body and pipe bracket and sensing port orifice With air supplied to the valve, move handle in either di-
in top of the diaphragm chamber are clean and unrestricted. rection from neutral to full travel position and hold. Adjust
To remove cam set screw Item #55, use of an impact graduating valve screw Item #40 to obtain the maximum
wrench (set soft) will break it loose to remove the cam and control pressure per Identity schedule. Move handle back to
shaft from cam housing. neutral position and note delivery line is exhausted to zero.
Examine all parts carefully. Replace all rubber parts and Move handle to full travel position in the opposite direction
all worn or damaged parts. The use of repair kits is recom- and the delivery pressure should be the same as the other
mended. side. If the delivery pressure is higher or lower by 2 to 3 psi
it can be corrected by adjusting the cam dog Item #18 with
Reassemble adjusting screw Item #19. Move the handle back to neutral
Refer to exploded Parts and Assembly Views. position and note delivery line is exhausted to zero.
Valves should always be reassembled using new rubber
parts. Cam Dog Adjustment
Lubricate all metal to metal wear surfaces with Lubriplate The eccentric cam dog screw Item #19 aligns the cam
107 Grease. Lubricate all the rubber parts, except the dia- follower Item #18 with the rise in the cam item #61. If the
phragm with Dow Corning No. 55 Pneumatic Grease. pressure setting is not within 2 to 3 psi from one full handle
The exhaust valve and seat if not replaced should be travel position to the other, turning the eccentric screw Item
polished for minimum leakage using a 600 grit-lapping com- #19 either clockwise or counter-clockwise can compensate
pound. Be sure to clean these parts prior to installing in the for the difference. This adjustment is accessible from the
valve. outside of the valve through the notch under the panel
Installing the cam set screw Item #55: The cam set screw flange using a long flat bladed screwdriver.
must be fully seated into the drill point location on the cam- The following procedure is recommended: move the valve
shaft, items #62 or #63. When installing set screw Item #55 handle to Full Travel in one direction (on detented models
use a thread locker like Loctite TL242. handle should be placed in detent position). Observe the
When installing the handle Item #53, seat the handle into output gage and note the pressure. Move the handle to the
the yoke, Item #52 before installing the nut, Item #51. opposite position, turn the eccentric cam follower screw
Do not over torque the cap nut, Item #60. Item #19 to half way between the pressure difference. Con-
tinue adjustment until delivery gages (ports 1 and 3) match
Adjustments within 2 to 3 psi of each other for related handle position.
Screw, Item #40 varies the graduated output pressure
setting. Screw Item #23 adjusts the opening of the side Special Preload Setting
valves and screw. Item #19 aligns the follower Item #18 This setting calls for a predetermined delivery pressure
with the cam Item #61. The nut Item #50 adjusts the brake when the handle is moved 10° from neutral in either direc-
tension on the HC-2-FX versions. tion.
Place handle 10° from neutral in either direction. Turn
Side Valve Lever Adjustments adjusting screw Item #40 in until the gage reads the desired
With air supplied to the valve, turn adjusting screw Item preload pressure. Move the handle to the maximum pres-
#40 in until the control spring Item #30 is slightly com- sure position. The delivery gage should read, preload pres-
pressed. Remove the snap rings and screens Item #15, 16 sure plus the range value of the control spring within ± 3 psi.
& 17. Move the Controlair Valve handle Item #53 back and Check handle setting in the opposite direction.
forth, both sides of the neutral position, observing the action
of the levers Items #20 & #22. The side valves should be Force Brake Adjustment
fully open after the handle moves the first 10 degrees of The handle force of the HC-2-FX Controlair Valve can be
travel. varied by adjusting nut Item #50 on the brake shoe holder
Move the control handle to a maximum pressure position. Item #47. This adjustment increases or decreases the force
With a 3/32” Allen wrench, back out adjusting screws Item required to move the handle in any position of the handle
#23 of the operated lever Items #20 or #22 just far enough travel.
to open the exhaust valve so that gage in the output line This adjustment is normally made on the cam housing
starts to show a drop in pressure. From this point, turn the portion before assembling to the control portion.
adjusting screw in a full three (3) turns. This will open the
inlet valve of the side valve to its maximum capacity.
Move the handle to the other extreme position and repeat
these adjustments on the other side valve lever.

Page 5
 DIAGRAMMATIC VIEW
VALVE
SYMBOL

2
LEGEND - PIPE BRACKET 1 IN 3
2 - SUPPLY-IN ®
8 - GRADUATED-DELIVERY HC-2 CONTROLAIR VALVE
1 - SIDE VALVE-DELIVERY
3 - SIDE VALVE-DELIVERY NEUTRAL

FULL TRAVEL
FULL TRAVEL 10° 10°

DUAL CAM

ADJUSTING SCREW

ADJUSTING SCREW
SIDE VALVE (3-WAY)
SIDE VALVE (3-WAY)

8 3
INLET & EXHAUST
VALVE UNIT
DIAPHRAGM
SUPPLY VALVE
SENSING PORT ORIFICE

EXHAUST VALVE RANGE CONTROL SPRING

EXHAUST PORT ADJUSTING SCREW

Page 6
 HC-2 IDENTITY SCHEDULE
Model New Old Control New Old New Cam Old Cam Portion New Valve Old Valve Remarks
Complete Complete Pressure Control Control Spring Part Number Part Number Part Number Part Number
Part Number Part Number Range (PSI) Spring P/N & Code (Ref. # 29) *Complete *Complete **Complete **Complete
R431002835 P –050975-00001 0 - 65 R431003732 P55442 Brown R431000134 -850253-00000 R431003829 P –055583-00001
R431002836 P –050975-00002 0 - 100 R431000043 526749 Yellow R431000134 -850253-00000 R431003830 P –055583-00002
R431002837 P –050975-00003 0 - 125 R431000099 540577 Light blue R431000134 -850253-00000 R431003831 P –055583-00003
R431002838 P –050975-00004 0 - 150 R431003731 P55441 Red R431000134 -850253-00000 R431003832 P –055583-00004
HC-2-X P –050975-00008 0 - 30 R431005475 P60295 Dark Blue R431000134 -850253-00000 R431003833 P –055583-00008
R434002034 P –052540-00004 0 - 150 R431005475 P55441 Red R431002978 P -052539-00000 R431003832 P –055583-00004 Note 1
R434002050 P –052878-00001 0 - 65 R431003732 P55442 Brown R431003028 P -052879-00000 R431003829 P –055583-00001 Note 2
R434001203 P –065238-00000 35 - 85 R431000099 P64822 Silver R431000134 -850253-00000 R431003835 P –055583-00016 Note 3
P –065689-00001 0 - 65 R431000099 P55442 Brown P -065690-00000 R431003829 P –055583-00001 Note 4
P –065689-00003 0 - 125 R431003732 540577 Light Blue R431007052 P -065690-0000 R431003831 P –055583-00003 Note 5
R434001176 P –067508-00003 0 - 125 R431000043 540577 Light Blue R431000140 P -067283-00000 R431003831 P –055583-00003 Note 6
R431002839 P –050976-00001 0 - 65 R431003732 P55442 Brown R431000140 -850259-00000 R431003829 P –055883-00001
R431002840 P –050976-00002 0 - 100 R431000043 526749 Yellow R431000140 -850259-00000 R431003830 P –055583-00002
R431002841 P –050976-00003 0 - 125 R431000099 540577 Light blue R431000140 -850259-00000 R431003832 P –055583-00003
R431002842 P –050976-00004 0 - 150 R431003731 P55441 Red R431000140 -850259-00000 R431003832 P –055583-00004
R431002843 P –050976-00008 0 - 30 R431005475 P60295 Dark Blue R431000140 -850259-00000 R431003833 P –055583-00008
R431002844 P –050976-00015 0 - 175 R431000099 P54159 Silver R431000140 -850259-00000 R431003834 P –055583-00015
R434001989 P –052943-00001 0 - 65 R431003732 P55442 Brown R431002810 P -065690-00000 R431003829 P –055583-00001 Note 7
HC-2-FX R434001976 P –055781-00001 0 - 65 R431000043 P55442 Brown R431002810 P -065690-00000 R431003829 P –055583-00001 Note 8
R434001219 P –065123-00001 0 - 65 R431003732 P55442 Brown R431000141 -850260-00000 R431003833 P –055583-00008 Note 9
P –065123-00002 0 - 100 R431000043 540577 Light blue R431000141 -850260-00000 R431003834 P –055583-00015 Note 10
R431006565 P –065123-00003 0 - 150 R431000099 P55441 Red R431000140 -850259-00000 R431003832 P –055583-00004 Note 11
P –063511-00001 0 - 65 R431003732 P55442 Brown P -065690-00000 R431003829 P –055583-00001 Note 12
P –063511-00003 0 - 100 R431000099 540577 Light blue R431000141 -850260-00000 R431003831 P –055583-00015 Note 13
P –063511-00004 0 - 150 R431003731 P55441 Red R431000140 -850259-00000 R431003832 P –055583-00004 Note 14
R431003824 P –055582-00001 0 - 65 R431003732 P55442 Brown R431000151 -850430-00000 R431003829 P –055883-00001
R431003825 P –055582-00002 0 - 100 R431000043 526749 Yellow R431000151 -850430-00000 R431003830 P –055583-00002
HC-2-LX R431003826 P –055582-00003 0 - 125 R431000099 540577 Light blue R431000151 -850430-00000 R431003831 P –055583-00003
R431003827 P –055582-00004 0 - 150 R431003731 P55441 Red R431000151 -850430-00000 R431003832 P –055583-00004
P –068520-00003 0 - 125 R431000099 540577 Light blue P -068525-00000 R431003831 P –055583-00003 Note 15
R431009114 P –051206-00001 0 - 65 R431003732 P55442 Brown R431002895 P -051207-00000 R431003829 P –055883-00001
R431002892 P –051206-00002 0 - 100 R431000043 526749 Yellow R431000151 -850430-00000 R431003830 P –055583-00002
R431002893 P –051206-00003 0 - 125 R431000099 540577 Light blue R4310001512 -850430-00000 R431003831 P –055583-00003
HC-2-SX R431002894 P –051206-00004 0 - 150 E321--3731 P55441 Red P -068525-00000 R431003832 P –055583-00004
R431002036 P –052518-00002 0 - 100 R431000043 526749 Yellow R431002987 P -052649-00000 R431003830 P –055583-00002 Note 16
R431002035 P –052518-00003 0 - 125 R431000099 540577 Light blue R431002987 P -052649-00000 R431003831 P –055583-00003 Note 17
R431007030 P –067197-00003 0 - 125 R431000099 540577 Light blue R431002896 P -051207-00001 R431003832 P –055583-00004 Note 18

* Cam Portion - less valve portion, pipe bracket, screws and nameplate ** Valve Portion - less pipe bracket, screws and cam portion.

Note 1- Same as R431002838 (P -050975-00004) except less yoke, handle and ball Items 52, 53 & 54
Note 2- Same as R431002835 (P -050975-00001) except long handle P -050979 Item 53
Note 3 - Same as P -050975-00000 press range setting.
Note 4 - Same as R431002835 (P -050975-00001) except items 38, 52 & 53 are chrome plated or stainless steel
Note 5 - Same as R431002837 (P -050975-00003) except items 38, 52 & 53 are chrome plated or stainless steel
Note 6 - Same as R431002835 (P -050975-00001) except item 56 is P50878-0002 and less centering spring
Note 7 - Same as R431002839 (P -050976-00001) except less escutcheon plate item 67.
Note 8 - Same as R431002839 (P -050976-00001) except less escutcheon plate and holes are plugged.
Note 9 - Same as R431002839 (P -050976-00001) except items 38, 52 & 53 are chrome plated or stainless steel
Note 10 - Same as R431002840 (P -050976-00002) except items 38, 52 & 53 are chrome plated or stainless steel
Note 11 - Same as R431002838 (P -050975-00004) except items 38, 52 & 53 are chrome plated or stainless steel
Note 12 - Same as R431002839 (P -050976-00001) except all exterior surfaces are painted with black epoxy paint.
Note 13 - Same as R431002841 (P -050976-00003) except all exterior surfaces are painted with black epoxy paint.
Note 14 - Same as R431002842 (P -050976-00004) except all exterior surfaces are painted with black epoxy paint.
Note 15 - Same as R431003826 (P -055582-00003) except items 38, 52 & 53 are chrome plated or stainless steel.
Note 16 - Same as R431002892 (P -051206-00002) except less yoke, handle and ball Items 52, 53 & 54.
Note 17 - Same as R431002893 (P -051206-00003) except less yoke, handle and ball Items 52, 53 & 54.
Note 18 - Same as R431002892 (P -051206-00003) except latches in opposite maximum pressure position.

Page 7
 EXPLODED VIEW
HC-2-X CONTROLAIR®
HC-2-LX CONTROLAIR®
HC-2-SX CONTROLAIR® 67
66
60 58 58 56
63 59 57 54

53
41 38
HC-2-FX CONTROLAIR® Stainless
Steel
61 Handle
60 65 64 62
55 52
45
44
51
47
46
48
49
50

28 27

21
24
20
37
22
18
36
19
25 23

5 17
30 16
15 P/N - R431006913
7 (P –066891-00000) Pipe
Bracket Portion Complete
35 3 (Ref. 1,2,3, 4)
31
2
34 68
69 1
32
35
29
4
39 NOTE:
1. SEE PAGE 9 FOR PART NUMBERS
33 42 2. SEE PAGE 10 FOR REPAIR KITS
3. MATCHED / LAPPED SET OF ITEM 34 & 42 ARE
40 IN KIT, P/N R431003892 (P –055687-00000 )

Page 8
 HC-2 Controlair® Valve Parts List
Ref. Qty. Description New HC-2-X Old HC-2-X New HC-2-LX Old HC-2-LX New HC-2-SX Old HC-2-SX New HC-2-FX Old HC-2-FX
Complete Device P –050975-0000X P –055582-0000X P –051206-0000X P –050976-0000X
1 1 Pipe Bracket R431006882 P –066812-00005 R431006882 P –066812-00005 R431006882 P –066812-00005 R431006882 P –066812-00005
2 **1 Filter R431006895 P -066849-00000 R431006895 P -066849-00000 R431006895 P -066849-00000 R431006895 P -066849-00000
3 **1 Gasket R431006889 P -066823-00000 R431006889 P -066823-00000 R431006889 P -066823-00000 R431006889 P -066823-00000
4 3 Screws R431002440 P -049902-00048 R431002440 P -049902-00048 R431002440 P -049902-00048 R431002440 P -049902-00048
Complete Bottom P55583-000X P55583-000X P55583-000X P55583-000X
5 1
Portion includes items 5 thru 33 Must specify spring range, same as last digit on valve
6 1 Complete Body Bushed w/item 7 R431002868 P -051112-00001 R431002868 P -051112-00001 R431002868 P -051112-00001 R431002868 P -051112-00001
7 1 Cartridge Valve See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits
8 2 Side Cartridge Valve w/2 "0" rings R431003741 P -055474-00002 R431003741 P -055474-00002 R431003741 P -055474-00002 R431003741 P -055474-00002
8A 2 Side Cartridge Vlv w/2 “0” rings including R431003985 P -057094-00001 R431003985 P -057094-00001 R431003985 P -057094-00001 R431003985 P -057094-00001
4 •Snap rings See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits
2 •Screens See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits
15 2 Snap Ring See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits
16 2 Screen See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits
17 2 Snap Ring See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits
18 **1 Cam Dog R431003014 P -052835-00000 R431003014 P -052835-00000 R431003014 P -052835-00000 R431003014 P -052835-00000
19 1 Cam Dog Pin R431002950 P -051856-00000 R431002950 P -051856-00000 R431002950 P -051856-00000 R431002950 P -051856-00000
20 1 Left Lever,includes Items 21, 23 & 24 R431004868 P -058978-00001 R431004868 P -058978-00001 R431004868 P -058978-00001 R431004868 P -058978-00001
21 1 Roller included with lever
22 1 Rt. Lever, includes items 21, 23 & 24 R431004871 P -058979-00001 R431004871 P -058979-00001 R431004871 P -058979-00001
23 1 Adjusting screw included with lever
24 1 Pin included with lever
25 *1 Nut See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits
27 1 Lever Pin R431002722 P -050686-00007 R431002722 P -050686-00007 R431002722 P -050686-00007 R431002722 P -050686-00007
28 2 Cotter Pins R431002541 P -049913-00001 R431002541 P -049913-00001 R431002541 P -049913-00001 R431002541 P -049913-00001
29 *3 Exhaust Valve Spring See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits
30 1 Control Springs See page 6 See page 6 See page 6 See page 6 See page 6 See page 6 See page 6 See page 6
31 1 Spring Seat R431000036 -526347-00000 R431000036 -526347-00000 R431000036 -526347-00000 R431000036 526347-00000
32 1 Spring Housing R431006822 P -066488-00002 R431006822 P -066488-00002 R431006822 P -066488-00002 R431006822 P -066488-00002
33 4 Mounting Nuts R431002419 P -049901-00020 R431002419 P -049901-00020 R431002419 P -049901-00020 R431002419 P -049901-00020
Graduating Valve includes items 21 &
34 *1 See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits
22
35 *2 3/4" "O"Rings See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits
36 *1 Washer See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits
1 Complete Top Portion R431000140 -850259-00000 R431000140 -850259-00000 R431000140 P -051207-00000 R431000140 850259-00000
37 *1 Diaphragm See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits
Complete Cam Housing includes Items
1 R431000087 -538261-00000 R431000079 -536908-00000 R4310028888 -536908-00000 R431000087 -538261-00000
38,39,40,41,63 & 64
38 *1 Cam Housing with bushing R431002766 P -050851-00002 R431002766 P -050851-00002 R431002766 P -050851-00002 R431002766 P -050851-00002
39 *1 "O" Ring See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits
40 1 Adjusting screw R431006770 P -066209-00000 R431006770 P -066209-00000 R431006770 P -066209-00000 R431006770 P -066209-00000
41 2 Studs R431002505 P -049906-00014 R431002505 P -049906-00014 R431002505 P -049906-00014 R431002505 P -049906-00014
42 *1 Exhaust Valve Seat See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits
Brake Assembly includes items 47,
43 1 See Repair Kits 850187 850187
48, 49, 50 & 65
44 1 Latch See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits
45 1 Latch Spring See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits
46 2 Rivets See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits
47 1 Brake Shoe & Holder See Repair Kits
48 1 Brake Spring See Repair Kits
49 1 Washer See Repair Kits

50 1 Nut See Repair Kits

51 1 Nut See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits
52 1 Yoke See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits
53 1 Handle Shaft See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits
54 1 Ball See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits
55 1 Stop Pin included with cam #61
56 1 Arbor R431000136 850254-00000 R431002597 P -049987-00002 R4310025697 P -049987-00002 R431002419 P -049901-00020
57 1 Spacer Washer See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits
58 2 Return Springs See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits
59 1 Arbor See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits
60 1 End Cap Nut R431003740 P -055465-00000 R431002505 P -049906-00014 R431002505 P -049906--00014 R431002409 P -049898-00009
61 1 Cam w/Stop Pin R431002796 P -050878-00003 R431002419 P -049901-00020 R431002419 P -049901-00020 R431002683 P -050600-00003
62 1 Cam Shaft See Repair Kits
63 1 Cam Shaft See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits
64 1 Woodruff Key R431002109 P -049767-00003
65 1 Brake Drum See Repair Kits
66 4 Screws R431002597 P -049987-00002 R431002597 P -049987-00002 R431002597 P -049987-00002 R431002597 P -049987-00002
67 1 Escutcheon Plate R431000072 536566-00000 R431000073 -536565-00001 R431000073 -536565-00000 R431000072 -536566-00000
68 2 Tooth Washers R431002409 P -049898-00009 R431002409 P -049898-00009 R431002409 P -049898-00009 R431002409 P -049898-00009
69 2 Mounting Nuts R431002419 P -049901-00020 R431002419 P -049901-00020 R431002419 P -049901-00020 R431002419 P -049901-00020

* These items are in the a minor repair kit for graduating section
** These items are in the major repair kit for graduating section.
See Page 10
For Repair Kits

Page 9
 Repair Kits for HC-2 Controlair® Valves
Quantity
New Part Number Old Part Number Description
per valve
R431003892 P -055687-00000 1 Minor Graduating Valve Portion-Repair Kit
Note 1 includes items 25, 29, 34, 35, 36, 37, 39 & 42
R431004005 P -057136-00000 1 Major Graduating Valve Portion-Repair Kit
Note 1 includes items 2, 3 & 18 and kit P55687
R431003741 P -055474-00002 2 Minor Side Valve Portion-Repair Kit
includes item 7 cartridge with "O" Rings
R431003985 P -057094-00001 2 Major Side Valve Portion-Repair Kit
includes snap rings, screen and kit P -055474-00002
R431006521 P -064894-00002 1 Complete Repair Kit for Control Portion -
Notes 1,2,3 & 4 includes (1) kit P -055687-00000,
(2) kits P -057094-00001, items 2, 3, 16 & 17
R431006415 P -064421-00001 1 Spring Latch Kit for LX and SX Models
Note 5 includes items 44, 45 & 46
R431000132 850187-00000 1 Friction Brake Kit for FX Models
Note 5 includes items 47, 48, 49, 50 & 65
R431006418 P -064421-00004 1 Cam Shaft Kit for FX Models
Note 5 includes items 51, 52, 53, 54 & 62
R431006419 P -064421-00005 1 Cam Shaft Kit for All Models
Note 5 includes items 51, 52, 53, 54 & 63
R431006423 P -064421-00009 1 Return Spring and Arbor Kit for X, LX & SX Models
Note 5 includes items 57, 58 & 59
R431006913 P -066890-00000 1 Pipe Bracket Portion Kit for all Models
includes items 1, 2, 3 & 4
R431006915 P -066891-00000

NOTES:
1. The inlet and exhaust valve unit Item 34 and exhaust valve seat Item 42 are lapped together to form
a matched set. Kits that contain these items from the factory include matched sets.
2. Select replacement range control spring from identity schedule on page 7.
3. All kits above include small tubes of the recommended lubricants.
4. Valve portion kits listed above contain the seals and other parts that are needed to repair the valve portion.
5. Replace all worn or damaged components, especially in the mechanical portions of the valve. The mechanical
parts are listed on pages 7, 8 and 9.

Chrome plated HC-2 Controlair® Valves

with chrome plated parts for item numbers listed
(See notes 4, 5, 9, 10, 11 and 15 --Page 7)
New Item 38 Old Item 38 New Item 52 Old Item 52 New Item 53 Old Item 53
New Part Old Part
Model Cam Housing Cam Housing Yoke Part Yoke Part Handle Shaft Handle Shaft
Number Number
Part Number Part Number Number Number Part Number Part Number
HC-2-
P –065689-00001 R431002769 P –050851-00008 R431006897 P –066852-00001 R431002846 P –050979-00001
X
P –065689-00003 R431002769 P –050851-00008 R431006897 P –066852-00001 R431002846 P –050979-00001
R431001219 P –065123-00001 R431002769 P –050851-00008 R431006897 P –066852-00001 R431002846 P –050979-00001
HC-2-
P –065123-00002 R431002769 P –050851-00008 R431006897 P –066852-00001 R431002846 P –050979-00001
FX
R431006565 P –065123-00003 R431002769 P –050851-00008 R431006897 P –066852-00001 R431002846 P –050979-00001
HC-2-
P –068520-00003 R431002769 P –050851-00008 R431006897 P –066852-00001 R431002846 P –050979-00001
LX

Page 10
 Testing and Test Set-Up
Testing B. Port (3)
After any repair or adjustments, the HC-2 Contro- 1. Repeat test A-1 for valves with 90 psi or
lair Valve should be tested using the following proce- less in opposite direction of the handle
dures and test arrangements. travel.
Pressure control valves need to be tested for the 2. Repeat test A-2 for valves with 100 psi or
following: more in opposite direction of the handle
1. Function 4. Flow Capacity travel.
2. Pressure Range 5. Response 4. Flow Capacity: Set supply line pressure to 100
3. Leakage 6. Mechanical Detents psi regardless of the control spring rating. Move
The adjustments affecting these points were de- the handle from neutral position in either direc-
scribed in the previous sections. tion to full travel position. The delivery volume (1)
General instructions for accomplishing these tests or (3) should start to fill within the time limits
are listed below. shown in Table 1.
1. Function: The HC-2 Controlair valve is a 4 way Move the handle quickly from full travel position
exhausted center valve capable of graduating back to neutral position. This should exhaust vol-
pressure in one or the other delivery lines. This ume (1) or (3) within the time limits shown on
function must be checked using the test arrange- table 1. Note valve with less than 0 to 35 psi or
ment to insure that only one volume is charged in less rated springs require an additional volume
either direction of handle travel. as shown in test arrangement diagram.
2. Pressure Range: The minimum and maximum 5. Response
pressure range generated in the delivery lines (1) A. Port (1) Move valve handle to the full travel
and (3) is specified by the control spring in use. position and hold. Fully open the valve at test
See the graduated output pressure setting Ad- volume (1) so that that the air exhausts
justment Section. After the valve is adjusted, through the choke plugs. Observe the deliv-
confirm that the minimum and maximum pres- ery pressure gage at volume (1). A pressure
sure ranges are generated in the delivery lines drop of no more than 3 psi permitted.
(1) and (3) as per the Identity Schedule by mov- B. Port (3) Repeat test 5A for opposite direction
ing the handle from neutral to first 10° then to the of handle travel.
full travel position on both sides of center. 6. Mechanical Detent (HC-2-LX or SX Models only):
3. Leakage: Set supply pressure to 20 psi above Move handle to extreme detent position. Connect
maximum delivery pressure of the valve being a spring scale just under the knob Item #54. The
tested. Using a soap and water solution, coat the force required to pull the handle out of detent
valve at the pipe bracket and spring housing position should be at least 12-lbs. Check detent
parting lines. No leakage is permitted in any han- hold in both extreme handle positions.
dle position.
Flow Capacity Tests- Ports 1 & 3
A. Port (1)
Test Ranges & Times
1. On all valves with spring ranges less than
Valve Fill Psi Maximum Exhaust Max. Test
90 psi., set supply line pressure to 100 psi, Range Time-Sec Psi Time Vol.
handle to full travel position and hold (detent 0 to15 0 to 15 15 to 5 450
psi psi 2 sec psi 2 sec. cu.in.
position on detented valves). Close valve in
0 to20 0 to 15 15 to 5 450
supply line to port (2) and valve in delivery psi psi 2 sec psi 2 sec. cu.in.
line (1) to isolate graduating valve. Observe 0 to25 0 to 15 15 to 5 450
2 sec 2 sec.
delivery pressure gage in line (1). A pressure psi psi psi cu.in.
0 to30 0 to 15 15 to 5 450
drop of no more than 2 psi in 30 seconds is psi psi 2 sec psi 2 sec. cu.in.
permitted. 0 to 35 0 to 15 15 to 5 450
psi psi 2 sec psi 2 sec. cu.in.

2. On all valves with spring ranges of 100 psi 0 to 65 0 to 50

2 sec.
50 to 10
2 sec.
225
psi psi psi cu. In.
and above, set supply line pressure to 100 0 to 50 50 to 10 225
0 to 100
psi. Move valve handle to deliver 95 psi to psi psi 2 sec. psi 2 sec. cu. In.
delivery line (1) and hold in that position. 0 to 125 0 to 50
2 sec.
50 to 10
2 sec.
225
psi psi psi cu. In.
Close valve in supply line to port (2) and
0 to 150 0 to 50 50 to 10 225
valve in port (1) delivery line to isolate the psi psi 2 sec. psi 2 sec. cu. In.
graduating valve. Observe the delivery gage 0 to 65 0 to 15 50 to 10 225
psi psi 2 sec. psi 2 sec. cu. In.
in line (1). A pressure drop of no more than 2
35 to 85 35 to 70 70 to 40 225
psi in 30 seconds is permitted. psi psi 2 sec. psi 2 sec. cu. In.

Page 11
 Test Arrangement Diagram

Notes:
1. Rexroth Taskmaster® Timing Volumes, part number R434002899 (TM–058887-00225) can be
used for the volumes indicated.
2. The supply air line to the valve and the delivery lines must be full size as shown. Line must not
exceed 3 Ft. between the supply valve and port (2), or between ports (1) & (3).
3. It is recommended that as large a gage as practical be used on the delivery lines. A 6” gage is
recommended.

REXROTH
P/N PD-020031-00191

RECOMMENDED: REXROTH
P/N R432016359
(PR-007816-00010)

Page 12
 NOTICE TO PRODUCT USERS
1. WARNING: FLUID MEDIA
Bosch Rexroth pneumatic devices are designed and tested for
use with filtered, clean, dry, chemical free air at pressures and
temperatures within the specified limits of the device. For use with
media other than air or for human life support systems, Bosch
Rexroth must be consulted. Hydraulic cylinders are designed for
operation with filtered, clean, petroleum based hydraulic fluid;
operation using fire-resistant or other special types of fluids may
require special packing and seals. Consult the factory.
2. WARNING: MATERIAL COMPATIBILITY
Damage to product seals or other parts caused by the use of
noncompatible lubricants, oil additives or synthetic lubricants in
the air system compressor or line lubrication devices voids Bosch
Rexroth's warranty and can result in product failure or other mal-
function. See lubrication recommendations below.
AIR LINE LUBRICANTS! In service higher than 18 cycles per
minute or with continuous flow of air through the device, an air
line lubricator is recommended.* (Do not use line lubrication with
vac-uum products.) However, the lubricator must be maintained
since the oil will wash out the grease, and lack of lubrication will
greatly shorten the life expectancy. The oils used in the lubricator
must be compatible with the elastomers in the device. The elas-
tomers are normally BUNA-N, NEOPRENE, VITON, SILICONE
and HYTREL. Bosch Rexroth recommends the use of only petro-
leum based oils without synthetic additives, and with an aniline
point between 180· F and 210· F.
COMPRESSOR LUBRICANTS! All compressors (with the excep-
tion of special "oil free" units) pass oil mist or vapor from the inter-
nal crankcase lubricating system through to the compressed air.
Since even small amounts of non-compatible lubricants can
cause severe seal deterioration (which could result in component
and system failure) special care should be taken in selecting com-
pati-ble compressor lubricants. It is recommended that users
review the National Fluid Power Association "Recommended
Guide Lines For Use Of Synthetic Lubricants In Pneumatic Fluid
Power Sys-tems" (NFPA T1.9.2-1978).
3. WARNING: INSTALLATION AND MOUNTING
The user of these devices must conform to all applicable electri-
cal, mechanical, piping and other codes in the installation, opera-
tion or repair of these devices.
INSTALLATION ! Do not attempt to install, operate or repair
these devices without proper training in the technique of work-
ing on pneumatic or hydraulic systems and devices, unless
under trained supervision. Compressed air and hydraulic sys-
tems con-tain high levels of stored energy. Do not attempt to
connect, dis-connect or repair these products when a system is
under pres-sure. Always exhaust or drain the pressure from a
system before performing any service work. Failure to do so
can result in seri-ous personal injury.
MOUNTING! Devices should be mounted and positioned in
such a manner that they cannot be accidentally operated.
4. WARNING: APPLICATION AND USE OF PRODUCTS
The possibility does exist for any device or accessory to fail to
operate properly through misuse, wear or malfunction. The
user must consider these possibilities and should provide ap-
propriate safe guards in the application or system design to
prevent per-sonal injury or property damage in the event of a
malfunction.
5. WARNING: CONVERSION, MAINTENANCE AND REPAIR
When a device is disassembled for conversion to a different
con-figuration, maintenance or repair, the device must be
tested for leakage and proper operation after being reassem-
bled and prior to installation.
MAINTENANCE AND REPAIR! Maintenance periods should
be scheduled in accordance with frequency of use and working
con-ditions. All Bosch Rexroth products should provide a mini-
mum of 1,000,000 cycles of maintenance free service when
used and lubricated as recommended. However, these prod-
ucts should be visually inspected for defects and given an "in
system" operating performance and leakage test once a year.
Where devices re-quire a major repair as a result of the one
million cycles, one year, or routine inspection, the device must
be disassembled, cleaned, inspected, parts replaced as re-
quired, rebuilt and tested for leakage and proper operation
prior to installation. See individ-ual catalogs for specific cycle
life estimates.
6. PRODUCT CHANGES
Product changes including specifications, features, designs
and availability are subject to change at any time without no-
tice. For critical dimensions or specifications, contact factory.
*Many Bosch Rexroth pneumatic valves and cylinders can
operate with or without air line lubrication; see individual sales
catalogs for details.

LIMITATIONS OF WARRANTIES & REMEDIES

Bosch Rexroth warrants its products sold by it to be free from defects in material and workmanship to the following:
For twelve months after shipment Bosch Rexroth will repair or replace (F.O.B. our works), at its option, any equipment which under
normal conditions of use and service proves to be defective in material or workmanship at no charge to the purchaser. No charge
will be made for labor with respect to defects covered by this Warranty, provided that the work is done by Bosch Rexroth or any of its
authorized service facilities. However, this Warranty does not cover expenses incurred in the removal and reinstallation of any prod-
uct, nor any downtime incurred, whether or not proved defective.
All repairs and replacement parts provided under this Warranty policy will assume the identity, for warranty purposes, of the part
replaced, and the warranty on such replacement parts will expire when the warranty on the original part would have expired. Claims
must be submitted within thirty days of the failure or be Subject to rejection.
This Warranty is not transferable beyond the first using purchaser. Specifically, excluded from this Warranty are failures caused by
misuse, neglect, abuse, improper operation or filtration, extreme temperatures, or unauthorized service or parts. This Warranty also
excludes the use of lubricants, fluids or air line additives that are not compatible with seals or diaphragms used in the products. This
Warranty sets out the purchaser's exclusive remedies with respect to products covered by it, whether for negligence or otherwise.
Neither, Bosch Rexroth nor any of its affiliates will be liable for consequential or incidental damages or other losses or .expenses
incurred by reason of the use or sale of such products. Our liability (except as to title) arising out of the sale, use or operation of any
product or parts, whether on warranty, contract or negligence (including claims for consequential or incidental damage) shalI not in
any event exceed the cost of replacing the defective products and, upon expiration of the warranted period as herein provided, all
such liability is terminated. THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, WHETHER
FOR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OR OTHERWISE. No attempt to alter, amend or extend
this Warranty shall be effective unless authorized in writing by an officer of Bosch Rexroth Corporation.
Bosch Rexroth reserves the right to discontinue manufacture of any product, or change product materials, design or specifications
without notice.

Page 13
 Bosch Rexroth Corporation
Pneumatics
1953 Mercer Road
Lexington, KY 40511-1021
Telephone (859) 254-8031
Facsimile (859) 254-4188
pneumatics@boschrexroth-us.com
www.boschrexroth-us.com /brp

International offices: Factory Automation North American offices: Bosch Rexroth Canada
Regional sales offices: Bosch Rexroth Corporation 3426 Mainway Drive
Asia: Corporate Headquarters Burlington, Ontario L7M 1A8 Telephone (905)
Central 5150 Prairie Stone Parkway 335-5511 Facsimile (905) 335-4184
China Russia
Bosch Rexroth Corporation Hoffman Estates, IL 60192-3707 www.boschrexroth.ca
India Singapore
5150 Prairie Stone Parkway Telephone (847) 645-3600
Japan South Korea
Hoffman Estates, IL 60192-3707 Facsimile (847) 645-0804 Bosch Rexroth, S.A. de C.V.
Malaysia
Telephone (847) 645-3600 Calle Neptuno # 72
Facsimile (847) 645-0804 Bosch Rexroth Corporation Unidad Industrial Vallejo
Australia
Industrial Hydraulics CP 07700 Mexico, D.F.
Great Lakes Telephone (555) 754-1711
Europe: 2315 City Line Road
Bosch Rexroth Corporation
Austria Netherlands Bethlehem, PA 18017-2131 Facsimile (555) 752-5943
2730 Research Drive
Belgium Norway Telephone (610) 694-8300
Rochester Hills, MI 48309
Bulgaria Poland Facsimile (610) 694-8467
Telephone (248) 393-3330
Czech Republic Portugal Further contacts:
Facsimile (248) 393-2893
Denmark Romania Bosch Rexroth Corporation www.boschrexroth.com/addresses
Finland Slovakia Northeast Electric Drives and Controls
France Spain Bosch Rexroth Corporation 5150 Prairie Stone Parkway
Germany Sweden 99 Rainbow Road Hoffman Estates, IL 60192-3707
Greece Switzerland East Granby, CT 06026-0000 Telephone (847) 645-3600
Hungary Turkey Telephone (860) 844-8377 Facsimile (847) 645-6201
Italy Ukraine Facsimile (860) 844-8595
United Kingdom Bosch Rexroth Corporation The data specified herein only
Bosch Rexroth Corporation Linear Motion and Assembly serves to describe the product. No
North America: 2315 City Line Road Technologies statements concerning a certain
Canada United States Bethlehem, PA 18017-2131 816 E. Third Street condition or suitability for a certain
Mexico Telephone (610) 694-8300 Buchanan, MI 49107 application can be derived from our
Facsimile (610) 694-8467 Telephone (269) 695-0151 information. The given information
Facsimile (269) 695-5363 does not release the user from
South America: Southeast obligation of own judgment and
Argentina Venezuela Bosch Rexroth Corporation verification. It must be remem-
Brazil 14001 South Lakes Drive
14001 South Lake Drive Charlotte, NC 28273 bered that our products are sub-
Charlotte, NC 28273-5544 ject to a natural process of wear
Telephone (800) 438-5983
Telephone (704) 583-4338 and aging. ©This document, as
Facsimile (704) 583-0523
Facsimile (704) 583-0523 well as the data, specifications and
other information set forth in it, are
Bosch Rexroth Corporation the exclusive property of Bosch
West
Mobile Hydraulics Rexroth Corp. Without their con-
Bosch Rexroth Corporation
145 Southchase Boulevard sent it may not be reproduced or
11 Goddard
Fountain Inn, SC 29644-9018 given to third parties.
Irvine, CA 92618-4600
Telephone (864)967-2777
Telephone (949) 450-2777
Facsimile (864)962-5338
Facsimile (949) 450-2790

Printed in the United States

©2008 Bosch Rexroth Corporation
SM-800.6505
(Supercedes B4-65.05)
October 2008