MAJOR REPAIR AND MAINTENANCE
ADJUSTMENTS
MAJOR REPAIR AND MAINTENANCE INSTRUTION
When it is determined that the CONTROLAIR
®
Valve requires
shop repairs (see page 2 for GENERAL MAINTENANCE AND
REPAIR RECOMMENDTIONS) the following general instruc-
tions are recommended:
DIASSEMBLY, CLEANING, AND LUBRICATION
Completely disassemble the CONTROLAIR
®
Valve. Wash all
metal parts in a non-flammable solvent. Rinse each part thor-
oughly and blow dry with a low pressure air jet. Arrange the
parts on a clean surface.
Inspect and clear screens, Items 2 & 16. Be sure all body and
bracket passages are clear and unrestricted. Be sure sensing
port orifice in top of diaphragm chamber is clear.
The cam set screw, Item 55, is locktighted or nylock type. An
impact wrench (set soft) will usually break it loose to remove the
cam and shaft.
Examine each part carefully. Replace all rubber parts and all
other worn or damaged parts. The use of REPAIR KITS is
strongly recommended, see page 13
.
REASSEMBLY
Refer to Exploded Parts and Assembly Views, pages 8, 11, 12.
Valve should be reassembled using new rubber parts and parts
indicated by Inspection.
As reassembly proceeds, lubricate all metal-to-metal wear sur-
faces with 107 Lubriplate Grease. Lubricate all rubber parts,
except diaphragm with No. 55 Dow Corning Pneumatic Grease.
Do not lubricate diaphragm.
The exhaust valve and seat may have to be slightly polished for
minimum leakage. If necessary, use BW valve lapping com-
pound (600+ grit)
The cam set screw, Item 55, must be fully seated into the drill
point location provided in the shaft, Item 62 or 63. Assemble
set screw, Item 55, with Loctite TL242.
Seat handle, Item 53, firmly into yoke threads before installing
the nut, Item 51.
Do not over torque the cap nut, Item 60.
ADJUSTMENTS AND TEST SET UP
The valve is factory set to provide the appropriate gradu-
ated pressure and mechanical operation per part number
(see Identity Schedule, page 6).
However, after the CONTROLAIR has been disassem-
bled, repaired and reassembled it must be adjusted and
tested for proper operation prior to returning to service.
It is recommended that the valve should be connected in a test
set up as shown on page 16.
ADJUSTMENTS
Screw (4) varies the graduated output pressure setting. Screw
(23) adjusts the opening of the side valve, and screw (19)
aligns the follower (18) with cam (61). In the HE-2-FX models,
nut (50) adjusts the brake tension.
GRADUATED OUTPUT PRESSURE SETTING
ADJUSTMENT
Adjusting screw (40) varies the maximum pressure setting.
Turning the adjusting screw in raises the maximum pressure,
turning it out decreases the maximum pressure. The
maximum control pressure adjustment should not exceed the
maximum control pressure shown in Identity Schedule, page 6,
for part number (control springs are color coded).
The maximum output pressure rating can be changed only be
changing the control spring (30). These springs are
interchangeable (see Identity Schedule, page 6).
With air supplied to the valve, move handle from “OFF” to full
travel position and hold. Adjust graduating valve adjusting
screw (40) to obtain the maximum specified delivery pressure
per Identity Schedule. Move handle back to “OFF” position
and note delivery line is exhausted to zero. Repeat test to
check maximum delivery pressure setting.
SIDE VALVE LEVER ADJUSTMENT
With air supplied to the valve, turn adjusting screw (4) until
control spring (30) is slightly compressed. Remove snap ring
(17) and screen (16). Move the CONTROLAIR Valve handle
(53) back and forth observing the action of lever (20). The
side valve should be fully open after the handle moves through
the first 10 degrees travel arc (clutch position). Place the
handle in the maximum increasing pressure position. With a
3/32” Allen Wrench, backout adjusting screw (23) of the
operated lever (20) just far enough to crack the exhaust valve
so that gauge will show a drop in pressure. From this point,
turn the adjusting screw in a full three (3) turns. This will open
the inlet valve of the side valve to its maximum capacity.
CAM DOG ADJUSTMENT
The eccentric cam dog screw (19) aligns the cam followers
(18) with the rise of cam (61). Minor adjustment to graduated
pressure from delivery line (8) can be made by turning the
follower eccentric screw (19) either clockwise or
counterclockwise. This adjustment is accessible from the
outside of the valve through a notch under the panel using a
long flat bladed screwdriver, cam follower screw (19).
FRICTION BRAKE ADJUSTMENT
The handle force of the HE-2-FX CONTROLAIR Valve can be
varied by adjusting nut (50) on brake shoe holder (47). This
adjustment increases or decreases the force required to more
the handle in any position of the handle travel.
This adjustment is normally made on cam housing portion
before assembly to control portion.
Page 14