Bosch Rexroth Corporation, Pneumatics

1953 Mercer Road, Lexington, KY 40511-1021

Tel: 859-254-8031 / Fax: 859-254-4188 or 800-489-4188
Email: pneumatics@boschrexroth-us.com
Web: www.boschrexroth-us.com

H-2 CONTROLAIR® VALVE

Service Information

Description of Models
The H-2 Type Controlair Valves are handle operated 3-
way pressure graduating control valves. The handle actu-
ates the pressure-graduating portion to increase, de-
crease or maintain a graduated air pressure to the deliv-
ery line.
When the handle is in the “OFF” or release position the Table of Contents Page
delivery line is connected to exhaust, except in the pre-
loaded type Controlairs. Handle movement from the Description of Models 1
“OFF” or release position actuates the pressure graduat- Warnings 2
ing portion to deliver a graduated pressure according to Technical Data 2
the value of the control spring. Installation 2
Maintenance/Repair Recommend. 2
Models Outline Dimensions 3&4
There are several models with similar valve functions, but Description of Operation 5
different handle operating characteristics. Maintenance and Repair 6
H-2-X Controlair Valve -Handle is spring returned to the Graphical Symbol 7
off position from all positions in the handle travel. Some Diagrammatic View 7
special models exist. See notes on Identity schedule on Identity Schedule 8&9
page 9. Exploded View 10
H-2-LX Controlair Valve - Handle is spring returned to off Part List 11 & 12
position from all positions except at the maximum pres- Repair Kit List 13
sure setting. The handle is held in the extreme position by Full Pressure Feature 14
a mechanical detent. Assembly Sectional Views 15 & 16
Testing 17
H-2-FX Controlair Valve - Handle is equipped with a
Function 17
friction brake that will hold the handle in any position se-
Pressure Range 17
lected in the handle travel.
Leakage 17
H-2-EX Controlair Valve - Handle is spring returned to
Flow Capacity 17
“OFF” position from all other positions in the handle travel.
Response 17
The “OUTLET” pressure increases from 0 to 40% of the
Mechanical Detents 17
control pressure in the first 60 degrees of handle travel.
Test Setup 17
The outlet pressure then increases to maximum control
Test Diagram 18
pressure in the remaining 32 degrees of handle travel.
H-2-EFX Controlair Valve - Handle travel and valve func-
tions are the same as H-2-EX except it is equipped with a
friction brake that holds the handle in any position se-
lected in the handle travel.
H-2-ES Controlair Valve - Valve is similar to H-2-EX ex-
cept no handle return spring or friction brake in the handle
travel.
H-2-EFS Controlair Valve- Valve is similar to H-2-EFX
except is preloaded in “release” position and handle return
spring is only effective in the first 28° of 86 degrees of
handle travel.
 Installation and General Maintenance Recommendations

WARNING: INSTALLATION AND GENERAL MAINTENANCE AND REPAIR

MOUNTING RECOMMENDATIONS
The user of these devices must conform to all appli-
cable electrical, mechanical, piping and other codes Maintenance periods should be scheduled in accordance
in the installation, operation or repair of these de- with frequency of use and working environment of the Con-
vices. trolair Valve.
All valves must be visually inspected for wear and given an
INSTALLATION! Do not attempt to install, oper- “In System” operating performance and leakage test at least
ate or repair these devices without proper train- once a year. If these visual observations indicate valve repair
ing in the technique of working on pneumatic or is required, the valve must be removed immediately and
hydraulic systems and devices, unless under repaired.
trained supervision. A major overhaul is recommended at one million cycles.
Compressed air and hydraulic systems contain However, where frequency of use is such that it would re-
high levels of stored energy. Do not attempt to quire more than two years to obtain the one million cycles,
connect, disconnect or repair these products the valve must be overhauled every two year period.
when a system is under pressure. Always ex- When it is determined that the Controlair Valve requires a
haust or drain the pressure from a system before major repair as a result of the one million cycles, one year
performing any service work. Failure to do so routine inspection or the two year service period has
can result in serious personal injury. elapsed, the device must be disassembled, cleaned, in-
MOUNTING! Devices should be mounted and spected, parts replaced as required. The valve then must be
positioned in such a manner that they cannot be tested for leakage and proper operation prior to installation,
accidentally operated. refer to the Major Repair and Maintenance Instructions and
test procedures.
Notice that the operating portion of the valve can be re-
Installation and General Mainte- moved without disturbing the pipe connections by just re-
nance Recommendations moving the (2) screws that hold the pipe bracket to the valve.
Before installing the Controlair Valve, all air lines in No special tools are required to maintain the Controlair
the system should be cleaned to remove all dirt, valves.
moisture or contamination. One complete Controlair valve should be kept in stock for
A strainer is furnished on the inlet port to protect the every (4) valves in service. During the maintenance period,
valve from large particles or foreign matter in the replacing the complete valve with the stand-by unit reduces
supply line. To insure long, trouble-free service, a 10 production down time and affords inspection and replace-
micron or better filter should be installed in the sup- ment of parts at a more appropriate time and favorable loca-
ply line to the valve. tion.
The H-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 in- Technical Data:
stallation view on pages 3 & 4 for panel opening
Max. Operating Pressure 200 PSI. (13.8 Bars)
dimension. Allow suitable clearance for installing or
removing of the (2) pipe bracket screws which are 1 Admissible Mediums Clean & Dry Compressed Air
1/2” long. Operating Temperature -40° to 160° F( - 40° to 71° C)
Hysteresis 1 1/2 Psi
Control Pressure Range Ref. Identity Chart on Page 8
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.)

Page 2
 Outline View
H-2 Controlair® Valve

Page 3
 Outline View
H2-E Controlair® Valve

.34 DIA 4.69

2.38
.38 R

1.00R
HOLE IN PANEL 1.50R
FOR MOUNTING 2.25

4.44
4.00

1.94
1.50R
2.00 1.00R

2.50
4.69

5.88R C

46°
1.63

92° YOKE
ASSEMBLY
AS SHOWN
1.50 REVERSE
FOR 78°

.31
.25 MAX.
THICKNESS
2.66 OF PANEL
OUT
IN

1.25 6.18
.62
TAP “B”
(2) PLACES

EXHAUSE OPENING

Page 4
 Description of Operation
For H-2 Controlair®

When the handle is in released position, the “IN” port is closed to supply pressure and the
“OUT” port is open to exhaust.
Note in the diagrammatic, when the handle is pushed forward to increase pressure, the cam
forces the cam follower to push down on the inlet and exhaust valve unit by closing the exhaust
valve and opening the supply. This permits air to flow to the “OUT” port and the upper dia-
phragm chamber. As the pressure builds up in the delivery line, it acts through the sensing port
orifice and deflects the control diaphragm downward, compressing the control spring. When
sufficient diaphragm deflection is obtained to allow the upper supply valve in the pressure con-
trol 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 movement in turn is controlled by the cam contour and is pro-
portional to the handle travel.
The H-2 Controlair Valve will automatically compensate for delivery (outlet) line air pressures
changes. These air pressure changes can be caused by line leakage, temperature change or
load feedback. If air pressure at the delivery (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 obtained. If the pressure drops be-
low that called for by the handle position 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 the delivery (outlet) line pressure is controlled by the strength of the
diaphragm spring.

Page 5
 Repair and Maintenance Instructions

Repair and Maintenance Instructions

When it has been determined that the Controlair Graduated Output Pressure Adjustments
Valve requires repairs, the following general instruc- Adjusting screw Item #1 varies the maximum pres-
tions are recommended. sure setting. Turning the adjusting screw in raises the
maximum pressure. Turning the screw out decreases
Disassembly, Cleaning and Lubrication the maximum pressure. The maximum control pres-
Completely disassemble the Controlair valve. sure adjustment should not exceed the maximum
Wash all metal parts in a non-flammable solvent. control pressure shown in the Identity Schedule for
Rinse each part thoroughly and blow dry with low that part number. (Control Springs are color coded).
pressure air. The maximum output pressure rating can be
Inspect and clean the inlet filter Item #17 and both changed by changing the control spring Item #5.
gaskets Item #18. Be sure all passages in the body With air supplied to the valve, move handle from
and pipe bracket and sensing port orifice in top of the neutral to full travel position and hold. Adjust graduat-
diaphragm chamber are clean and unrestricted. ing valve screw Item #1 to obtain the maximum con-
To remove cam set screw Item #40, use of an im- trol pressure per Identity schedule. Move handle
pact wrench (set soft) will break it loose to remove back to neutral position and note delivery line is ex-
the cam and shaft from cam housing. hausted to zero.
Examine all parts carefully. Replace all rubber
parts and all worn or damaged parts. The use of re- Special Preload Setting
pair kits is recommended. This setting calls for a predetermined delivery pres-
sure.
Reassemble
Refer to exploded Parts and Assembly Views. Friction Brake Adjustment
Valves should always be reassembled using new The handle force of the H-2-FX, H-2-EFX and H-2-
rubber parts. EFS Controlair Valve can be varied by adjusting nut
Lubricate all metal to metal wear surfaces with Lu- Item #50 on the brake shoe holder Item #47. This
briplate 107 Grease. Lubricate all the rubber parts, adjustment increases or decreases the force required
except the diaphragm with Dow Corning No. 55 to move the handle in any position of the handle
Pneumatic Grease. travel. Factory setting is 8 lbs (3.6 Kgs)
The exhaust valve and seat if not replaced should This adjustment is normally made on the cam
be polished for minimum leakage using a 600 grit housing portion before assembling to the control por-
lapping compound. Be sure to clean these parts prior tion.
to installing in the valve.
Installing the cam set screw Item #40. The cam set
screw must be fully seated into the drill point location
on the cam shaft Item #36. When installing set screw
Item #40 use a thread locker like Loctite TL242.
Installing the handle (Item #43), seat the handle
into the yoke, Item #42 before installing the nut, Item
#44.
Do not over torque the cap nut, Item #44.

Adjustments
There are 3 adjustments that can be made to the
H-2 Controlair Valves. The adjusting screw item #1
that varies the output pressure, reversing the handle
yoke item #42 can effect the degrees of handle travel
from 92 to 78 degrees and friction brake item #47
increases or decreases the force required to move
the control handle.

Page 6
 DIAGRAMMATIC VIEW
VALVE
SYMBOL

IN OUT

H-2 CONTROLAIR® VALVE

RELEASE POSITION FULL TRAVEL

LEGEND—PIPE BRACKET

CAM IN - SUPPLY
OUT - GRADUATED DELIVERY

CAM FOLLOWER

INLET & EXHAUST SENSING PORT ORIFICE

VALVE UNIT

SUPPLY VALVE DIAPHRAGM

EXHAUST VALVE

ADJUSTING SCREW
EXHAUST PORT

Page 7
 H-2 IDENTITY SCHEDULE
+Model Complete Part Control Pressure Control Spring & Cam Portion Valve Portion Handle Remarks
Number Range (PSI.) Color Code Complete Complete Travel
P50493-0001 0 to 65 Psi. P55442 Brown 850426 P55510-0001 92 Deg.
P50493-0002 0 to 100 Psi. 526749 Yellow 850426 P55510-0002 92 Deg.
P50493-0003 0 to 125 Psi. 540577 Lt. Blue 850426 P55510-0003 92 Deg.
P50493-0004 0 to 150 Psi. P55441 Red 850426 P55510-0004 92 Deg.
P50493-0005 0 to 15 Psi. P60293 White 850426 P55510-0005 92 Deg.
P50493-0008 0 to 30 Psi. P60295 Dark Blue 850426 P55510-0008 92 Deg.
H-2-X P50493-0011 10 to 65 Psi. P55442 Brown 850427 P55510-0001 78 Deg.
P65989-0003 0 to 125 Psi. 540577 Lt. Blue P65990 P55510-0003 92 Deg. Note 1
P67191 0 to 100 w/FP 540577 Lt. Blue 850426 P63408-0003 92 Deg. Note 4
P67694-0003 0 to 125 Psi. 540577 Lt. Blue P65990-0001 P55510-0003 92 Deg. Note 2
P68542-0007 0 to 25 Psi. P60295 Dark Blue P68454 P68453-0007 92 Deg. Note 5
P68543-0003 0 to 125 Psi. 540577 Lt. Blue P65990 P55510-0003 92 Deg. Note 6
P68544-0003 0 to 125 Psi. 540577 Lt. Blue P65990 P55510-0003 92 Deg. Note 7
P68758-0001 0 to 65 Psi. P55442 Brown P68454-0001 P55510-0001 92 Deg. Note 3
P50494-0001 0 to 65 Psi. P55442 Brown 850261 P55510-0001 92 Deg.
P50494-0002 0 to 100 Psi. 526749 Yellow 850261 P55510-0002 92 Deg.
P50494-0003 0 to 125 Psi. 540577 Lt. Blue 850261 P55510-0003 92 Deg.
P50494-0004 0 to 150 Psi. P55441 Red 850261 P55510-0004 92 Deg.
P50494-0005 0 to 15 Psi. P60293 White 850261 P55510-0006 92 Deg.
P50494-0007 0 to 25 Psi. P60295 Dark Blue 850261 P55510-0008 92 Deg.
P50494-0008 0 to 30 Psi. P60295 Dark Blue 850261 P55510-0008 92 Deg.
P50494-0010 0 to 80 Psi. 531418 Dark Green 850261 P55510-0010 92 Deg.
P50494-0011 10 to 65 Psi. P55442 Brown 850265 P55510-0001 78 Deg.
P50494-0012 10 to 90 Psi. 531418 Dark Green 850265 P55510-0010 78 Deg.
P50494-0015 0 to 175 Psi. P54159 Silver 850261 P55510-0015 92 Deg.
P50494-0016 3 to 15 PSI P64822 Silver 850265 P55510-0016 78 Deg.
P51248-0011 10 to 65 Psi. P55442 Brown P51429 P55510-0001 92 Deg. Note 9
P52490-0001 0 to 65 Psi. P55442 Brown P51429 P55510-0001 92 Deg. Note 10
P52490-0008 0 to 30 Psi. P60295 Dark Blue P51429 P55510-0008 92 Deg. Note 10
P52929-0002 0 to 100 Psi. 526749 Yellow P52877 P55510-0002 92 Deg. Note 8
P55863-0001 0 to 65 Psi. P55442 Brown P57053 P55510-0001 78 Deg. Note 18
P55863-0002 0 to 100 Psi. 526749 Yellow P57053 P55510-0002 92 Deg. Note 18
P55863-0003 0 to 125 Psi. 540577 Lt. Blue P57053 P55510-0003 92 Deg. Note 18
P55863-0010 0 to 80 Psi. 531418 Dark Green P57053 P55510-0010 92 Deg. Note 18
P58998 0 to 65 Psi. P55442 Brown 850265 P55510-0001 92 Deg. Note 20
P63407-0002 0 to 100 Psi w/FP 526749 Yellow 850261 P63408-0002 92 Deg. Note 19
P64092-0004 0 to 150 Psi. P55441 Red 850261 P55510-0004 92 Deg. Note 11
P65124-0001 0 to 65 Psi. P55442 Brown P65129 P55510-0001 92 Deg. Note 12
H-2-FX P65124-0002 0 to 100 Psi. 526749 Yellow P65129 P55510-0002 92 Deg. Note 12
P65124-0003 0 to 125 Psi. 540577 Lt. Blue P65129 P55510-0003 92 Deg. Note 12
P65124-0004 0 to 150 Psi. P55441 Red P65129 P55510-0004 92 Deg. Note 12
P65607-0011 10 to 65 Psi. P55442 Brown P65610 P55510-0001 92 Deg. Note 12
P67460-0011 10 to 70 Psi. P55442 Brown P65610-0001 P55510-0001 92 Deg. Note 23
P68521-0002 0 to100 Psi. 526749 Yellow P68522 P55510-0002 92 Deg. Note 13
P68548-0003 0 to 125 Psi. 540577 Lt. Blue P68522-0002 P55510-0003 78 Deg. Note 22
P68549-0001 0 to 65 Psi. P55442 Brown P68522-0001 P55510-0001 78 Deg. Note 22
P68549-0002 0 to 100 Psi. 526749 Yellow P68522-0001 P55510-0002 92 Deg. Note 22
P68549-0003 0 to 125 Psi. 540577 Lt. Blue P68522-0001 P55510-0003 92 Deg. Note 22
P68549-0010 0 to 80 Psi. 531418 Dark Green P68522-0001 P55510-0010 92 Deg. Note 22
P50499-0001 0 to 65 Psi. P55442 Brown 850428 P55510-0001 92 Deg.
P50499-0002 0 to 100 Psi. 526749 Yellow 850428 P55510-0002 92 Deg.
P50499-0003 0 to 125 Psi. 540577 Lt. Blue 850428 P55510-0003 92 Deg.
P50499-0004 0 to 150 Psi. P55441 Red 850428 P55510-0004 92 Deg.
P50499-0009 0 to 75 Psi. 531418 Dark Green 850428 P55510-0010 92 Deg.
H-2-LX P50499-0011 10 to 65 Psi. P55442 Brown 850429 P55510-0001 78 Deg.
P50499-0012 10 to 90 Psi. 531418 Dark Green 850429 P55510-0010 78 Deg.
P66325-0003 0 to 125 Psi. 540577 Lt. Blue P66326 P55510-0003 92 Deg. Note 14
P68545-0003 0 to 125 Psi. 540577 Lt. Blue P66326-0003 P55510-0003 92 Deg. Note 16
P68546-0003 0 to 125 Psi. 540577 Lt. Blue P66326-0002 P55510-0003 92 Deg. Note 15
P68547-0003 0 to 125 Psi. 540577 Lt. Blue P66326-0001 P55510-0003 92 Deg. Note 17
P50925-0001 0 to 65 Psi. P55442 Brown P50926 P55513-0001 92 Deg.
P50925-0002 0 to 100 Psi. 526749 Yellow P50926 P55513-0002 92 Deg.
P50925-0003 0 to 125 Psi. 540577 Lt. Blue P50926 P55513-0003 92 Deg.
H-2-EX P50925-0005 0 to 15 Psi. P60293 White P50926 P55513-0005 92 Deg.
P66322-0002 0 to 100 Psi. 526749 Yellow P66323 P55513-0002 92 Deg. Note 24
P67224-0002 0 to 100 Psi. 526749 Yellow P67274 P55513-0002 92 Deg. Note 27
P67576-0002 0 to 100 Psi. 526749 Yellow P67274-0001 P55513-0002 92 Deg. Note 25
P67577-0002 0 to 100 Psi. 526749 Yellow P50926-0001 P55513-0002 92 Deg. Note 26
P51846-0001 0 to 65 Psi. P55442 Brown P51847 P55513-0001 92 Deg.
P51846-0002 0 to 100 Psi. 526749 Yellow P51847 P55513-0002 92 Deg.
H-2-EFX P51846-0003 0 to 125 Psi. 540577 Lt. Blue P51847 P55513-0003 92 Deg.
P51846-0004 0 to 150 Psi. P55441 Red P51847 P55513-0004 92 Deg.
P53217-0001 0 to 65 Psi. P55442 Brown P53218 P55513-0001 92 Deg. Note 29
P55763-0001 0 to 65 Psi. P55442 Brown P53218 P55513-0001 92 Deg. Note 28
H-2-E P62293-0002 0 to100 526749 Yellow P62292 P55513-0002 92 Deg.
H-2-EFS P63247-0003 10 to 110 Psi. 540577 Blue P63298 P55513-0003 86 Deg.
P63247-0004 12 to 125 Psi. P55441 Red P63298 P55513-0004 86 Deg.

Page 8
 Identity Schedule

Note 1 - Same as P50493-0003 except Items 23 & 42 are chrome plated.

Note 2 - Same as P50493-0003 except cam housing and escutcheon plate, Item 23 and 25, piece numbers
P67695 or P48316.
Note 3 - Same as P50493-0001 except less yoke, handle, nut, knob and paint, Items 42,43,44 & 45.
Note 4 - Same as P50493-0003 except with full pressure feature (special valve portion consult factory).
Note 5 - Same as P50493-0008 except special non-magnetic materials (consult the factory)
Note 6 - Same as P50493-0003 except Items 22, 23, 35,36, 37 and 39 are replaced with piece numbers
P65690-0003, P67695-0002, P50800, P67225-0001, P67223 and P49804-0069.
Note 7 - Same as P68543-0002 except Items 22, 23 and 25 are replaced with P65990-0002,
P67695 and P48316.
Note 8 - Same as P50494-0002 except Item 43 is piece number P50979 (long handle shaft).
Note 9 - Same as P50494-0011 except special non-magnetic material (consult the factory).
Note 10 - Same as P50494-00XX except Items 22, 23, and 25 are replaced by piece numbers P52491,
P52492 and less Item 25.
Note 11 - Same as P50494-00XX except with black epoxy paint.
Note 12 - Same as P50494-00XX except Items 23 & 42 are chrome plated.
Note 13 - Same as P50494-0002 except Items 22, 23, and 25 are replaced with piece numbers P68522
P67695-0001 and P48316.
Note 14 - Same as P50499-0003except Items 42 and 43 are chrome plated.
Note 15 - Same as P50499-0003 except Items 22, 23 and 25 are replaced with P65990-0002, P67695
and P48316.
Note 16 - Same as P50499-0003 except Items 22, 23, 35,36, 37 and 39 are replaced with piece numbers
P66326-0003, P66237-0003, P68643, P67225-0001, P67223 and P49707-0004.
Note 17 - Same as Note 16 except Items 22, 23 and 25 are replaced with P65990-0002, P67695 and
P48316.
Note 18 - Same as P50494-00XX except (Right Hand Pull Action) Items 22, 23, 35 and 36 are replaced
with piece numbers P57053, P67695, P48316 and P5988.
Note 19 - Same as P50494-0002 except with full pressure feature (special valve portion consult factory).
Note 20 - Same as P50494-0001 except with sprocket drive (Obsolete).
Note 21 - Same as P50494-0001 except has 9/16-18 straight thread “O” ring ports
Note 22 - Same as P50494-XXXX except (Right or Left Hand Pull Action) Items 22, 23, 35 and 36 are
replaced with piece numbers P68522-0002, P67695-0002, P64198, P67225 and P49804-0069.
Note 23 - Same as P50494-XXXX except less Items 43,44 and 45 and Items 22 and 36 are replace with
65610-0001, P67459 and (1) screw P/N P50283-0005.
Note 24 - Same as P50295-0002 except Items 23 & 42 are chrome plated.
Note 25 - Same as P50925-0002 except (Left Hand Pull Action) and Items 22 & 23 are replaced piece
numbers P50926-0001 and P50927-0002.
Note 26 - Same as P50925-0002 except (Left Hand Push Action) less Items 37 & 39 and Items 22, 23,
35 and 36 are replaced with piece numbers P67274-0001, P50927-0003, P50600-0002,
and P67225-0001 plus arbor spring P67223 and spacer P67226 are added.
Note 27 - Same as P50925-0002 except (Right Hand Push Action) less Items 37 & 39 and Items 22, 23,
35 and 36 are replaced with piece numbers P67274, P50927-0004, P50600-0002, and
P67225-0001 plus arbor spring P67223 and spacer P67226 are added.
Note 28 - Same as P51846-0001 except less Item 25 with holes plugged for the escutcheon drive
screws.
Note 29 - Same as P51846-0001 except less Item 25.

Page 9
 EXPLODED VIEW
H-2-X CONTROLAIR®
H-2-LX CONTROLAIR®
NOTE:
41 39 38 37 1. SEE PAGE 11 & 12 FOR PART NUM-
36
BERS
2. SEE PAGE 13 FOR REPAIR KITS
3. MATCHED/LAPPED SET OF ITEM 8 &
13 ARE IN KIT, P/N P –055687-00000 45
PAGE 11.

H-2-EFX CONTROLAIR
H-2-EFS CONTROLAIR (has spring (38), arbor (37) and brake).
H-2-FX CONTROLAIR 43
36
41 46
16

23 42
47
BRAKE ASSY. 32
PART NO. 48 35 44
850182 49
50 40

21 27

19 28
20
30
9
SEE PAGE 13 FOR
REPAIR KITS
NOTE 7
8
3
17
6
18
34 51
10 33
IN
11
OUT
12

5
52
4
14
2
13 NOTE 3

14
3
15

Page 10
 H-2 Controlair® Valve Parts List
REF. QTY. DESCRIPTION H-2-X H-2-FX H-2-LX

Complete Device P –050493-0000X P –050494-0000X P –050499-0000X

1 1 Adjusting screw P –066209-00000 P –066209-00000 P –066209-00000

2 1 Spring Housing P –066488-00002 P –066488-00002 P –066488-00002
3 4 Nuts P –049901-00020 P –049901-00020 P –049901-00020
4 1 Spring Seat 526347 526347 526347
5 1 Control Springs See page 6 See page 6 See page 6
6 1 Complete Body 534200 534500 534500
7 2 Cap Screws P –049842-00000 P –049842-00000 P –049842-00000
Minor Graduating Portion
**1 P –055687-00000 P –055687-00000 P –055687-00000
Includes Items 8 to 14
8 *1 Exhaust Valve Seat See Repair Kits See Repair Kits See Repair Kits
9 *1 11/16” “O” Ring See Repair Kits See Repair Kits See Repair Kits
10 *1 Diaphragm See Repair Kits See Repair Kits See Repair Kits
11 *1 Diaphragm Follower See Repair Kits See Repair Kits See Repair Kits See Page 13
12 *1 Adjusting Screw See Repair Kits See Repair Kits See Repair Kits for Repair Kits
13 *1 Inlet & Exhaust Valve/Includes 14 See Repair Kits See Repair Kits See Repair Kits summary.
14 *2 3/4” “O” Rings See Repair Kits See Repair Kits See Repair Kits
15 **1 Exhaust Valve Spring See Repair Kits See Repair Kits See Repair Kits
Complete Bottom Portion P –055510-0000X P –055510-0000X P –055510-0000X
15A 1
Includes items 1 to 15 Must specify spring range, same as last digit on valve
16 1 Brake Drum 850181 850181 850181
17 **1 Strainers See Repair Kits See Repair Kits See Repair Kits
18 **2 Gaskets See Repair Kits See Repair Kits See Repair Kits
Major Graduating Repair Kit P –059028-00000 P –059028-00000 P –059028-00000
**1
Includes Kit P –055687-00000 and Items 15, 17 and 18
19 1 Pivot Pin P –048189-00000 P –048189-00000 P –048189-00000
20 2 Retaining Rings P –049528-00001 P –049528-00001 P –049528-00001
21 1 Cam Dog P –052835-00000 P –052835-00000 P –052835-00000
Complete Top Portion
22 1 850426 850426 850426
Includes items 23,33 to 50
Complete Cam Housing
23 1 534496 534496 536795
Includes items 24 to 32
24 1 Cam Housing (Bushed) P –050851-00002 P –050851-00002 P –050851-00002
25 1 Escutcheon Plate 534491-1 534491-1 534491-1
26 1 Stop P –050851-00003 P –050851-00003 P –050851-00003
27 1 Latch Spring X X 539961
28 1 Latch X X P –057117-00000
29 2 Rivets Large P –049533-00001 P –049533-00001 P –049533-00001
30 2 Rivets Small P –049854-00004 P –049854-00004 P –049854-00004
31 4 Screws #6—3/16” P –049987-00002 P –049987-00002 P –049987-00002
32 2 Studs P –049906-00014 P –049906-00014 P –049906-00014

33 2 Mounting Nuts P –049901-00020 P –049901-00020 P –049901-00020

34 2 Tooth Washers P –049898-00009 P –049898-00009 P –049898-00009
35 1 Cam w/pin P –050800-00002 P –050800-00000 P –050800-00002
36 1 Cam Shaft See Repair Kits See Repair Kits See Repair Kits
37, 38 1 Return Spring & Arbor Kit P –064421-00008 X P –064421-00008
39 1 Cam Shaft Sleeve 850400 X 850400
40 1 Screw 5/16” - 18 x 5/8” P –048746-00001 P –048746-00001 P –048746-00001
41 1 Cap Nut See Repair Kits See Repair Kits See Repair Kits
42 1 Handle Yoke See Repair Kits See Repair Kits See Repair Kits
43 1 Handle Shaft See Repair Kits See Repair Kits See Repair Kits
44 1 Nut See Repair Kits See Repair Kits See Repair Kits
45 1 Handle Ball See Repair Kits See Repair Kits See Repair Kits
46 1 Key 1/8 x 5/8” X P –049767-00003 X
Brake Shoe & Holder Kit
1 X 850187 X
Includes items 47, 48, 49 & 50
47 1 Brake Shoe & Holder X See Repair Kits X
48 1 Nut X See Repair Kits X
49 1 Washer X See Repair Kits X
50 1 Elastic Stop Nut X See Repair Kits X
51 1 Bracket P –066888-00000 P –066888-00000 P –066888-00000
52 2 Screws 3/18-24 x 1 1/4” P –049902-00042 P –049902-00042 P –049902-00042

* These items are in the minor repair kit for graduating section.

** These items are in the major repair kit for graduating section.
 H-2 Controlair® Valve Parts List
REF. QTY DESCRIPTION H-2-EX H-2-EFX H-2-ES H-2-EFS
Complete Device P –050925-0000X P –051846-0000X P –062293-00003 P –063247-0000X
1 1 Adjusting Screw P –066209-00000 P –066209-00000 P –066209-00000 P –066209-00000
2 1 Spring Housing P –066488-00002 P –066488-00002 P –066488-00002 P –066488-00002
3 4 Nuts P –049901-00020 P –049901-00020 P –049901-00020 P –049901-00020
4 1 Spring Seat 526347 526347 526347 526347
5 1 Control Springs See Page 6 See Page 6 See Page 6 See Page 6
6 1 Complete Body 534200 534500 534500 534500
7 2 Cap Screws P –049842-00000 P –049842-00000 P –049842-00000 P –049842-00000
Minor Graduating Portion
**1 P –055687-00000 P –055687-00000 P –055687-00000 P –055687-00000
Includes Items 8 to 14
8 *1 Exhaust Valve Seat See Repair Kits See Repair Kits See Repair Kits See Repair Kits
9 *1 11/16” “O” Ring See Repair Kits See Repair Kits See Repair Kits See Repair Kits
10 *1 Diaphragm See Repair Kits See Repair Kits See Repair Kits See Repair Kits
11 *1 Diaphragm Follower See Repair Kits See Repair Kits See Repair Kits See Repair Kits
12 *1 Adjusting Screw See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Page 13
13 *1 Inlet & Exhaust Valve/Includes 14 See Repair Kits See Repair Kits See Repair Kits See Repair Kits for Repair Kits
14 *2 3/4” “O” Rings See Repair Kits See Repair Kits See Repair Kits See Repair Kits summary.
15 **1 Exhaust Valve Spring See Repair Kits See Repair Kits See Repair Kits See Repair Kits
15A 1 Complete Bottom Portion P –055513-0000X P –055513-0000X P –055513-0000X P –055513-0000X
Portion includes items 1 to 15 Must specify spring range, same as last digit on valve
16 1 Brake Drum X 850181 X P –063297-00000
17 **1 Strainers See Repair Kits See Repair Kits See Repair Kits See Repair Kits
18 **2 Gaskets See Repair Kits See Repair Kits See Repair Kits See Repair Kits
**1 Major Graduating Repair Kit P –059028-00000 P –059028-00000 P –059028-00000 P –059028-00000
Includes Kit P –055687-00000 and Items 15, 17 and 18
19 1 Pivot Pin P –048189-00000 P –048189-00000 P –048189-00000 P –048189-00000
20 2 Retaining Rings P –049528-00001 P –049528-00001 P –049528-00001 P –049528-00001
21 1 Cam Dog W/ Bearing & Follow P –050140-00001 P –050140-00001 P –050140-00001 P –050140-00001
Complete Top Portion
22 1 P -050926-00000 P –051847-00000 P –062292-00000 P –063298-00000
Includes items 23,33 to 50
Complete Cam Housing
23 1 P –050927-00000 P –050927-00000 P –050927-00000 P –063299-00000
Includes items 24 to 32
24 1 Cam Housing (Bushed) P –050851-00002 P –050851-00002 P –050851-00002
25 1 Escutcheon Plate P –049197-00006 P –049197-00006 P –049197-00006 P –049197-00005
26 1 Stop P –050851-00003 P –050851-00003 P –050851-00003 P –050851-00003
27 1 Latch Spring X X X X
28 1 Latch X X X X
29 2 Rivets Large P –049533-00001 P –049533-00001 P –049533-00001 P –049533-00001
30 2 Rivets Small X X P –049854-00004 X
31 4 Screws #6—3/16” P –049987-00002 P –049987-00002 P –049987-00002 P –049987-00002
32 2 Studs P –049906-00014 P –049906-00014 P –049906-00014 P –049906-00014
33 2 Mounting Nuts P –049901-00020 P –049901-00020 P –049901-00020 P –049901-00020
34 2 Tooth Washers P –049898-00009 P –049898-00009 P –049898-00009 P –049898-00009
35 1 Cam w/pin P –050600-00003 P –050600-00002 P –050600-00002 P –050600-00002
36 1 Cam Shaft See Repair Kits See Repair Kits See Repair Kits P –063294-00001
37 1 Arbor Handle Return See Repair Kits X X P –063296-00000
38 1 Handle Return Spring See Repair Kits X X 850256
39 1 Cam Shaft Sleeve 850400 X X X
40 1 Screw 5/16” - 18 x 5/8” P –048746-00001 P –048746-00001 P –048746-00001 P –048746-00001
41 1 Cap Nut See Repair Kits See Repair Kits See Repair Kits P –055465-00000
42 1 Handle Yoke See Repair Kits See Repair Kits See Repair Kits P –063295-00000
43 1 Handle Shaft See Repair Kits See Repair Kits See Repair Kits 850460
44 1 Nut See Repair Kits See Repair Kits See Repair Kits P –049859-00000
45 1 Handle Ball See Repair Kits See Repair Kits See Repair Kits 517026
46 1 Key 1/8 x 5/8” X P –049767-00003 X P –049767-00003
Brake Shoe & Holder Kit
1 X 850187 X 850187
Includes items 47, 48, 49 & 50
47 1 Brake Shoe & Holder X See Repair Kits X See Repair Kits
48 1 Nut X See Repair Kits X See Repair Kits
49 1 Washer X See Repair Kits X See Repair Kits
50 1 Elastic Stop Nut X See Repair Kits X See Repair Kits
51 1 Bracket P –066888-00000 P –066888-00000 P –066888-00000 P –066888-00000
52 2 Screws 3/18-24 x 1 1/4” P –049902-00042 P –049902-00042 P –049902-00042 P –049902-00042
53 1 Nut X X X P –049901-00023
54 1 Screws X X X P –049856-00046
X=NOT USED IN THIS DEVICE
* These items are in the minor repair kit for graduating section.
** These items are in the major repair kit for graduating section.
 Repair Kits for H-2 Controlair® Valves
Quantity
Piece Number Description
Per Valve

* P –055687-00000 Minor Graduating Valve Portion-Repair Kit

1
Note 1 Includes items 8, 9, 10, 11, 12, 13 and 14
* P –059028-00000 Major Graduating Valve Portion-Repair Kit
1
Note 1 Includes items 15, 17, 18 and Kit P –055687-00000
850187 Friction Brake Kit for FX, EFX and EFS models
1
Note 5 Includes items 47, 48, 49 and 50
P –064421-00006 Cam Shaft Kit for X, FX, LX, EX, EFX and ES
1
Note 5 Includes items 36, 41, 42, 43, 44 and 45
P –064421-00008 Return Spring and Arbor Kit for X and LX
1
Note 5 Includes items 37 and 38
P –064421-00010 Return Spring and Arbor Kit for EX
1
Note 5 Includes items 37 and 38

Notes:
*1. The inlet and exhaust valve unit Item 13 and exhaust valve seat Item 8 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 8.
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 9, 10, 11 and 12.

Chrome plated H-2 Controlair® Valves

with chrome plated parts for item numbers listed
(See notes 1, 12, 14 and 24 --Page 9)
Model Complete Item 23 Item 42 Item 43
Part Number Cam Housing Yoke Handle Shaft
Part Number Part Number Part Number
H-2-X P –065989-00003 P –065130-00000 P –066852-00001 P –050979-00001
P –065124-00001 P –065130-00000 P –066852-00001 P –050979-00001
H-2-FX P –065124-00002 P –065130-00000 P –066852-00001 P –050979-00001
P –065124-00003 P –065130-00000 P –066852-00001 P –050979-00001
H-2-LX P –066325-00003 P –066237-00000 P –066852-00001 P –050979-00001
H-2-EX P –066322-00002 P –066237-00000 P –066852-00001 P –050979-00001

Page 13
 Full Pressure Feature for H-2 Controlair®
The full pressure feature was added to H-2 Controlair Valves to provide pressure graduation for
the initial engagement of a clutch and then to lock the clutch at full line pressure. It is particu-
larly attractive on valves that are mounted in a vertical position. The full pressure feature
makes it easier for the operator to hold the valve fully engaged for period of time. When the top
pressure is critical, it compensates for valve component wear.
Caution must be exercised when using this feature. The full pressure feature opens
to full line pressure, so this pressure may need to be regulated to the value desired.

Line

Full Pressure Kit P/N P –067190-00000

FULL PRESSURE POINT

PRESSURE
Exhaust Valve Nut IS ADJUSTABLE.
Stop Rod
Adjusting Screw
Set Screw
HANDLE TRAVEL
GRADUATION WITH FULL PRESSURE FEATURE

HANDLE TRAVEL

Normal setting is
10 - 15 before full
travel.

Nut

Adjustable
Max. Travel

Rod

Adjustable
Screw
Set Screw

Page 14
 C

A A A

92° YOKE ASSEMBLY

AS SHOWN REVERSE
ASSEMBLY FOR 78°

Page 15
ASSEMBLY VIEW

A A
A
H-2-FX CONTROLAIR® VALVE H-2-X & H-2-LX CONTROLAIR® VALVE
 ASSEMBLIES
The following H-2-X, H-2-LX, and H-2-FX CONTROLAIR Valves are assembled as shown where handle
location or push/pull handle action is required on special panel configuration.

Page 16
 Testing and Test Set-Up (See Test Arrangement Diagram)

Testing 4. Flow Capacity: Set supply line pressure to 100

After any repair or adjustments, the H-2 Controlair psi (6.9 bar) regardless of the control spring rating.
Valve should be tested using the following procedures Moving the handle from “OFF” position to the full
and test arrangements described in this section. travel position, the delivery volumes should start to
Pressure control valves need to be tested for the fol- fill within the time limits shown in Table 1.
lowing: Move the handle quickly from full travel position
1. Function 4. Flow Capacity to back to “OFF” position. This should exhaust
2. Pressure Range 5. Response volumes within the time limits shown on table 1.
3. Leakage 6. Mechanical Detents Note: valves with less than 0 to 35 psi (2.4 bar)
The adjustments affecting these points were described or less rated springs require an additional volume
in the previous sections. as shown in test arrangement diagram.
General instructions for accomplishing these tests are 5. Response: Move valve handle to the full travel
listed below. position and hold. Fully open the valve at test vol
1. Function: The H-2 Controlair Valves are spring re- ume so that that the air exhausts through the choke
turned handle actuated 3-way pressure graduating plug. Observe the delivery pressure gage at volume
valves. The handle actuates the valve to increase, (1). A pressure drop of no more than 3 psi (0.2 Bar)
decrease or maintain graduated air pressure to the is permitted.
“OUT” port or delivery line. 6. Mechanical Detent (H-2-LX): Move handle to ex-
2. 2. Pressure Range: Supply pressure at “IN” port treme detent position. Connect a spring scale just
will be delivered as graduated pressure to the under the knob. A minimum of 12 lbs. should be
“OUT” or delivery port depending upon the range of required to pull the handle out of detent.
the control spring being used and the handle
position. The handle in the “OFF” or returned
position the “OUT” or delivery port is at minimum Flow Capacity Tests- Ports 1 & 3
pressure setting. Moving the handle actuates the
graduating control portion to deliver graduated
Test Ranges & Times
pressure to the “OUT” or delivery port. Check the
valve to confirm the Minimum Pressure of 30 psi Valve Fill Psi Maximum Exhaust Max. Test
(2 Bar) and Maximum pressure of 70 psi Range Time-Sec Psi Time Vol.
0 to15 0 to 15 2 sec 15 to 5 2 sec. 450
(4.9 Bar). psi psi psi cu.in.
3. Leakage: Set supply pressure to 20 psi (1.4 Bar) 0 to20 0 to 15 2 sec 15 to 5 2 sec. 450
psi psi psi cu.in.
above maximum delivery pressure of the valve
being tested. Using soap and water solution, coat 0 to25 0 to 15 2 sec 15 to 5 2 sec. 450
psi psi psi cu.in.
the valve at the pipe bracket and spring housing
0 to30 0 to 15 2 sec 15 to 5 2 sec. 450
parting lines. No leakage is permitted in any handle psi psi psi cu.in.
position. 0 to 35 0 to 15 2 sec 15 to 5 2 sec. 450
psi psi psi cu.in.
A. Port (IN)
0 to 65 0 to 50 2 sec. 50 to 10 2 sec. 225
1. On all valves with spring ranges less than psi psi psi cu. In.
90 psi (6.2 bar), set supply line pressure to 0 to 100 0 to 50 2 sec. 50 to 10 2 sec. 225
100 psi (6.9 bar). Move handle to full travel psi psi psi cu. In.
0 to 125 0 to 50 2 sec. 50 to 10 2 sec. 225
position and hold (detent position on detented psi psi psi cu. In.
valves). Close valve in supply line to “IN” port 0 to 150 0 to 50 2 sec. 50 to 10 2 sec. 225
or delivery line to isolate graduating valve. psi psi psi cu. In.

Observe delivery pressure gage in line. A 0 to 65

psi
0 to 15
psi
2 sec. 50 to 10
psi
2 sec. 225
cu. In.
pressure drop of no more than 2 psi (0.14 bar) 35 to 85 35 to 70 2 sec, 70 to 40 2 sec. 225
in 30 seconds is permitted. psi psi psi cu. In.

Page 17
 Test Arrangement Diagram
Notes:
1. Rexroth Taskmaster Timing Volumes, part number 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.
(1 meter) between the supply valve and “IN” or supply port or “OUT” or delivery port.
3. It is recommended that as large of a gage as practical be used on the delivery lines. A 6” (150mm) test gage is
recommended.

PR-7816-10

SM-800.6502
(Supercedes B4-65.02)
September 2004

Page 18