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Repair and Maintenance Instructions
Repair and Maintenance Instructions
When it has been determined that the Controlair
®
Valve
requires repairs, the following general instructions are
recommended.
Disassembly, Cleaning and Lubrication
Completely disassemble the Controlair valve. Wash all
metal parts in a non-flammable solvent. Rinse each part
thoroughly and blow dry with low pressure air.
Inspect and clean the inlet filter Item #2 and gasket Item #3
(older models had multiple gaskets that are still supplied in
the repair kits). Be sure all passages in the body and pipe
bracket and sensing port orifice in top of the diaphragm
chamber are clean and unrestricted.
To remove cam set screw Item #55 use of an impact
wrench (set soft) will break it loose to remove the cam and
shaft form cam housing.
Examine all parts carefully. Replace all rubber parts and
all worn or damaged parts.
The use of repair kits is
recommended.
Reassemble
Refer to exploded Parts and Assembly Views.
Valves
should always be reassembled using new rubber parts.
Lubricate all metal to metal wear surfaces with Lubriplate
107 Grease. Lubricate all the rubber parts,
except the
diaphragm
with Dow Corning No. 55 Pneumatic Grease.
The exhaust valve and seat if not replaced should be
polished for minimum leakage using a 600 grit lapping
compound. Be sure to clean these parts prior to installing
in the valve.
Installing the cam set screw Item #55. The cam set screw
must be fully seated into the drill point location on the cam
shaft, Items #62 or #63. When installing set screw Item
#55 use a thread locker like Loctite TL242.
Installing the handle Item #53, seat the handle into the
yoke. Item #52 before installing the nut, Item #51.
Dot not over torque the cap nut, Item #60.
Adjustments
Screw, Item #40 varies the graduated output pressure
setting. Screws Item #23 adjust the opening of the side
valves and screw, Item #19 aligns the follower Item #18
with the cam Item #61. The nut Item #50 adjusts the brake
tension of the HG-2 FX versions.
Side Valve Lever Adjustments
With air supplied to the valve, turn adjusting screw Item
#40 in or until the control spring Item #30 is slightly
compressed. Remove the snap rings and screens Items #
16 and 17. Move the Controlair Valve handle Item #53
back and forth, both sides of the neutral position, observing
the action of the lever Item #20. The side valve should be
fully open after the handle moves the first 10 degrees of
travel.
Move the control handle to a maximum pressure position.
With 3/32” Allen Wrench, back out adjusting screws Items
#23 of the operated lever #20 just far enough to open the
exhaust valve so that gauge in the output line starts to
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.
Move the handle to the other extreme position and repeat
these adjustments on the other side valve lever.
Graduated Output Pressure Adjustments
Adjusting screw Item #40 varies the maximum pressure
setting. Turning the adjusting screw in raises the
maximum
pressure. Turning the screw out decreases the
maximum
pressure. The maximum control pressure
adjustment should not exceed the maximum control
pressure shown in the Identity Schedule for that part
number. (Control Springs are color coded.)
The maximum output pressure rating can be changed by
changing the control spring Item #30.
With air supplied to the valve, move handle from neutral to
full travel position and hold. Adjust graduating valve screw
Item #40 to obtain the maximum control pressure per
Identity schedule. Move handle back to neutral position
and
note
delivery line is exhausted to zero. If the delivery
pressure is higher or lower by 2 to 3 psi (0.14 to 0.21 bar) it
can be corrected by adjusting the cam dog Item #18 with
adjusting screw Item #19. Move the handle back to neutral
position and
note
delivery line is exhausted to zero.
Cam Dog Adjustment
The eccentric cam dog screw Item #19 aligns the cam
follower Item #18 with the rise in the cam Item #61. If the
pressure setting is not within 2 to 3 psi from one full handle
travel position to the other, the difference can be
compensated for by turning the eccentric screw Item #19
either clockwise or counter-clockwise. This adjustment is
accessible from the outside of the valve through the notch
under the panel flange using a long flat bladed screw
driver.
The following procedure is recommended: move the valve
handle to Full Travel in one direction (on detented models
handle should be placed in detent position). Observe the
output gage and note the pressure. Move the handle to
the opposite position, turn the eccentric cam follower screw
Item #19 to half way between the pressure difference.
Continue adjustment until delivery gages (1 and 3) match
within 2 to 3 psi (0.14 to 0.21 bar) of each other for related
handle position.
Force Brake Adjustment
The handle force of the HG-2-FX Controlair Valve can
be varied by adjusting nut Item #50 on the brake shoe
holder Item #47. This adjustment increases or decreases
the force required to move the handle in any position of
the handle travel.
This adjustment is normally made on the cam housing
portion before assembling to the control portion. Factory
setting is 8 lbs.
