Maintenance And Repair - Aventics CONTROLAIR HC-2 Series Service Information

Repair and Maintenance Instructions
Repair and Maintenance Instructions
When it has been determined that the Controlair
requires repairs, the following general instructions are rec-
ommended.
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. Be sure all pas-
sages 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 from cam housing.
Examine all parts carefully. Replace all rubber parts and
all worn or damaged parts. The use of repair kits is recom-
mended.
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 dia-
phragm 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 com-
pound. 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.
When installing the handle Item #53, seat the handle into
the yoke, Item #52 before installing the nut, Item #51.
Do not over torque the cap nut, Item #60.
Adjustments
Screw, Item #40 varies the graduated output pressure
setting. Screw Item #23 adjusts 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 on the HC-2-FX versions.
Side Valve Lever Adjustments
With air supplied to the valve, turn adjusting screw Item
#40 in until the control spring Item #30 is slightly com-
pressed. Remove the snap rings and screens Item #15, 16
& 17. Move the Controlair Valve handle Item #53 back and
forth, both sides of the neutral position, observing the action
of the levers Items #20 & #22. The side valves should be
fully open after the handle moves the first 10 degrees of
travel.
Move the control handle to a maximum pressure position.
With a 3/32" Allen wrench, back out adjusting screws Item
#23 of the operated lever Items #20 or #22 just far enough
to open the exhaust valve so that gage 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
®
Valve 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 part numbers. (Control springs are
color-coded).
Changing the control spring Item #30 can change the
maximum output pressure rating.
With air supplied to the valve, move handle in either di-
rection 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.
Move handle to full travel position in the opposite direction
and the delivery pressure should be the same as the other
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
adjusting screw Item #19. Move the handle back to neutral
position and note delivery line is exhausted to zero.
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, turning the eccentric screw Item
#19 either clockwise or counter-clockwise can compensate
for the difference. This adjustment is accessible from the
outside of the valve through the notch under the panel
flange using a long flat bladed screwdriver.
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. Con-
tinue adjustment until delivery gages (ports 1 and 3) match
within 2 to 3 psi of each other for related handle position.
This setting calls for a predetermined delivery pressure
when the handle is moved 10° from neutral in either direc-
tion.
Place handle 10° from neutral in either direction. Turn
adjusting screw Item #40 in until the gage reads the desired
preload pressure. Move the handle to the maximum pres-
sure position. The delivery gage should read, preload pres-
sure plus the range value of the control spring within ± 3 psi.
Check handle setting in the opposite direction.
The handle force of the HC-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.
Page 5
Cam Dog Adjustment
Special Preload Setting
Force Brake Adjustment