Professional Documents
Culture Documents
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
Page 2
Outline View
HC-2 Controlair® Valve
Page 3
Description of Operation
For HC-2 Controlair®
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
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 - 125 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 R431002841 (P -050976-00003) 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
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
R431003895 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
R431003743 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.
Page 10
Testing and Test Set-Up
Testing
After any repair or adjustments, The HC-2 Controlair A. Port 8 is plugged.
Valve should be tested using the following procedures
and test arrangements described in this section. B. Ports 1 and 3: For valves with a spring range of
Pressure control valves need to be tested for the less than 90 psi, set the supply line pressure to at
following least 100 psi. Move the handle in either direction to
1. Function 4. Leakage the full travel position and hold . Then close the
2. Pressure Range 5. Mechanical Detents supply line to port #2 or delivery line to isolate the
3. Directional Output graduating valve. Observe the gage in the delivery
line. A pressure drop of no more than 2 psi in 30
The adjustments affecting these points were described in seconds is permitted.
the previous sections.
General instructions for accomplishing this test are listed C. For valves with a spring range of more than 100
below using a 3 way 3 position valves with closed center. psi, set the supply line pressure to at least 15 psi
To test the valve for function, pressure range and above the spring range. Move the handle in either
directional output if using an AVENTICS “D” Pilotair direction to the full travel position and hold . Then
Valve place handle in position 1.To test for leakage place close the supply line to port #2 (or move the handle
handle in position 2. To remove the valve after these of PD-020031-00191 valve) to the center position to
tests are performed move handle to position 3. isolate the graduating valve. Observe the gage in the
delivery line. A drop of no more than 2 psi in 30
1. Function: The HC-2 Controlair Valve has 2 pressure seconds is permitted pressure.
regulated airlines. The selection between the pressure
regulated airlines depends on the movement of the D. Shut –off the supply line after testing to vent
handle to either side of neutral or center position. The downstream lines. Move the handle of the directional
pressure or regulated line output is proportional to the valve to position 3, this will insure supply line 2 is
handle position on either side of the neutral position. exhausted. Shut –off the ball valve before the
regulator to insure that that line is also vented
2. Pressure Range: The minimum and maximum
pressure range is generated in delivery lines 1 and 3 and 4. Mechanical Detent: (HC-2-LX or SX Models only):
is specified by the control spring in use. See the Move the handle to the extreme detented position.
graduated output pressure setting adjustment section. Connect a spring scale just under the knob item #54. The
After the valve is adjusted confirm the minimum and force required to pull the handle out of the detented
maximum pressure is generated in delivery lines 1 and 3 position should be at least 12 lbs. Check the detent hold
by moving the handle from neutral to 10° then to full in both extreme handle positions.
travel position both sides of center.
Page 11
Test Arrangement Diagram
Notes:
1. AVENTICS 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.
IN
AVENTICS
1 2 3 R431009857
(PD-020032-000191)
Legend—Valve
R431016359
(PR-007816-00010)
Handle Position Function
1 Supply
2 Block
3 Exhaust
Page 12
NOTICE TO PRODUCT USERS
1. WARNING: FLUID MEDIA INSTALLATION ! Do not attempt to install, operate or re-
AVENTICS pneumatic devices are designed and tested for use pair these devices without proper training in the technique of
with filtered, clean, dry, chemical free air at pressures and tem- working on pneumatic or hydraulic systems and devices, un-
peratures within the specified limits of the device. For use with less under trained supervision. Compressed air and hydraulic
media other than air or for human life support systems, AVEN- systems con-tain high levels of stored energy. Do not attempt
TICS must be consulted. Hydraulic cylinders are designed for to connect, dis-connect or repair these products when a sys-
operation with filtered, clean, petroleum based hydraulic fluid; tem is under pres-sure. Always exhaust or drain the pressure
operation using fire-resistant or other special types of fluids may from a system before performing any service work. Failure to
require special packing and seals. Consult the factory. do so can result in seri-ous personal injury.
2. WARNING: MATERIAL COMPATIBILITY MOUNTING! Devices should be mounted and positioned in
Damage to product seals or other parts caused by the use of such a manner that they cannot be accidentally operated.
noncompatible lubricants, oil additives or synthetic lubricants in 4. WARNING: APPLICATION AND USE OF PRODUCTS
the air system compressor or line lubrication devices voids AVEN- The possibility does exist for any device or accessory to fail to
TICS warranty and can result in product failure or other mal- operate properly through misuse, wear or malfunction. The
function. See lubrication recommendations below. user must consider these possibilities and should provide ap-
AIR LINE LUBRICANTS! In service higher than 18 cycles per propriate safe guards in the application or system design to
minute or with continuous flow of air through the device, an air prevent per-sonal injury or property damage in the event of a
line lubricator is recommended.* (Do not use line lubrication with malfunction.
vac-uum products.) However, the lubricator must be maintained 5. WARNING: CONVERSION, MAINTENANCE AND REPAIR
since the oil will wash out the grease, and lack of lubrication will When a device is disassembled for conversion to a different
greatly shorten the life expectancy. The oils used in the lubricator con-figuration, maintenance or repair, the device must be test-
must be compatible with the elastomers in the device. The elasto- ed for leakage and proper operation after being reassembled
mers are normally BUNA-N, NEOPRENE, VITON, SILICONE and and prior to installation.
HYTREL. AVENTICS recommends the use of only petroleum MAINTENANCE AND REPAIR! Maintenance periods
based oils without synthetic additives, and with an aniline point should be scheduled in accordance with frequency of use and
between 180· F and 210· F. working con-ditions. All AVENTICS products should provide a
minimum of 1,000,000 cycles of maintenance free service
COMPRESSOR LUBRICANTS! All compressors (with the
when used and lubricated as recommended. However, these
excep-tion of special "oil free" units) pass oil mist or vapor from
products should be visually inspected for defects and given an
the inter-nal crankcase lubricating system through to the com-
"in system" operating performance and leakage test once a
pressed air. Since even small amounts of non-compatible lubri-
year. Where devices re-quire a major repair as a result of the
cants can cause severe seal deterioration (which could result in
one million cycles, one year, or routine inspection, the device
component and system failure) special care should be taken in
must be disassembled, cleaned, inspected, parts replaced as
selecting compati-ble compressor lubricants.
3. WARNING: INSTALLATION AND MOUNTING required, rebuilt and tested for leakage and proper operation
The user of these devices must conform to all applicable electri- prior to installation. See individ-ual catalogs for specific cycle
cal, mechanical, piping and other codes in the installation, opera- life estimates.
6. PRODUCT CHANGES
tion or repair of these devices.
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 AVENTICS pneumatic valves and cylinders can operate
with or without air line lubrication; see individual sales catalogs
for details.
Page 13
AVENTICS Corporation
1953 Mercer Road
Lexington, KY 40511
www.aventics.com/us
info.us@aventics.com
AVENTICS Incorporated
Burlington, Ontario CANADA
www.aventics.com/ca
info.ca@aventics.com