ELECTRO-HYDRAULIC

SERVO VALVE

Bharat Heavy Electricals Limited

Tiruchirapalli

PUB.NO.7111

Index
 CONTENTS
INTRODUCTION
COMMISSIONING, ADJUSTING AND CHECKING
MAINTENANCE
SERVO VALVE ST 10-63/R6 TYPE 6771-. (PARTS LIST)
SERVO-VALVE ST 10-4/R6 TYPE 6770-(PARTS LIST)
SERVO-VALVE ST 10-4 R 6 Z (PARTS LIST)
INSTRUCTIONS FOR THE ASSEMBLY OF DIAPHRAGM
INSTRUCTIONS FOR ASSEMBLY OF CONTROL FORK WITH SPOOL

2
Index
1. INTRODUCTION
(i) General
The servo valve is a part of the complete electro-hydraulic servo-system. See the diagram "
Electro-Hydraulic Servo System " showing the relationship to the electric and hydraulic
circuits.
(ii) Application
The electro- hydraulic servo-valve transforms the control signals coming from the electronic
amplifier into hydraulic pressures.
(iii) Layout and Function
The servo valve consists of an upper electro- magnetic and a lower hydraulic part.
(a) Electro-magnetic Part
The control signal is introduced via the plug and socket terminals (25) a and b (c is for an
earth connection, if necessary). Two permanent magnets 9 create a magnetic circuit through
the baseplate 12 and the armature 34, in which 2 separate parallel paths of the same strength
are formed by the specially shaped pole shoes (Fig. 1 ). As soon as the current Is, of a control
voltage Us., flows through the 2 coils, magnetic lines are generated (Fig. 2).
The resultant magnetic field is shown in Fig. 3, showing that the armature moves towards the
stronger field.
This movement of the ball-bearing supported armature is transmitted to the control fork via
the distance-piece 32 and the coupling plate 31.
The torque is approximately proportional to the magnetic flux s, and therefore to the control
current Is, At the maximum deflection, i.e. at 11.5 V and 1W, the torque is about 500 gcm.
To reduce the effects of friction and residual magnetism, an AC voltage is superimposed onto
the DC control signal in the amplifier when on " Automatic " control, which causes a slight
continuous vibration of the armature 34.
FIG. 1 FIG. 2 FIG. 3

(b) Hydraulic Part

The hydraulic part transforms the movement of the central fork into equivalent control oil
pressures. The control spool is designed to act as an amplifier system with an internal feedback
When the lower portion of the control fork moves, for examp!e, to the left, then the left-hand
control orifice of the spool 13 is uncovered and the oil passes from the pilot control oil space
Vst 1 into the oil leakage space Lo (see Section V-V).

3
Index
 Since the pressure oil supply P is throttled via the pilot control oil space Vst into the pilot
control space Vst1 through the filter 20 and a small hole in the filter plug, the pressure in the
control oil space Vst1 drops slightly below the pressure of the oil in space Vst 2.
Because of the resulting pressure difference the spool 13 moves to the left until both control
orifices throttle equally again. Thus the spool follows the movement of the control fork
continuously. Hydraulic reaction forces act practically at right angles to the direction of
movement of the fork, so that the power needed to move the spool is very small; in other
words, the servo-valve has a very high amplification factor.
When the spool is moved from its middle position, it allows the hydraulic oil to flow to one
side of the actuator piston and the return oil to flow back from the other side.
The fork (for R6 only) can be moved manually in either direction by means of the push
button 1, overriding any automatic control signals which may be present.
If movement of the spool is prevented (blocked filter, blocked throttle holes in the filter
carrier or in the spool itself), then it can be moved mechanically by means of the levers 26 in
an emergency.
2. COMMISSIONING, ADJUSTING AND CHECKING
(i) Functional Test
The function of the servo valve is to be checked (Sec. 2. ii) after any maintenance work has
been done.
(ii) Adjusting the Control Fork
This shall only be performed incase of doubts that midposition of control fork(44) is nomore
correct.
This operation can only be carried out on the installed servo valve if valve movements are
permitted in terms of system operation. It must be possible to move the actuator. Strict
cleanliness is essential.
Procedure:
- Manually move blocking unit to open position (by lifting levers of manual control.)
- Remove the power supply plug from servo valve.
- Move the actuator to midposition by manual control of lever.
- Return manual control levers to initial position.
- Observe the movement of actuator from mid position.
- No movement (or) slow drifting towards CLOSE direction is O.K and acceptable.
- Incase of fast movement / drifting of valve in middle position, the spring frame(53)
is to be adjusted till small drifting towards closing direction is achieved.
Setting of control fork:
- Remove the four screws on cover of the electircal parts of servo valve and remove
the cover and seal.
- Slightly loosent the four fixing screws of frame (53).
- Adjust the setting frame (53) of the centering springs until the actuator only drifts
to a minimum towards closing direction of the valve. Tighten screws.
- Check the movement of actuator in both directions by manaual deflection of

4
Index
 control fork by feather touch only. Forcibly pulling the control fork can cause
control fork bend.
- Putback seal and refix cover (4 screw wit h tinsion washers).
- Connect the power supply plug to servo valve and manually close Blocking
Unit (move downwards lever of manual control).
3. MAINTENANCE
(i) General
If the hydraulic part of a servo valve must be dismantled, it is essential that this is done only
by trained personnel.
It is of utmost importance that this work is carried out only under clean conditions. This
requirement can usually be met only if the valves are situated in a special room. Otherwise it
is recommended to remove the complete unit from the blocking unit and from the oil lines (4
bolts in hydraulic part). The servo valve can then be dismantled and cleaned as described
below.
If a reserve servo valve is fitted, then it should be replaced when the first unit is functioning
again. In this way one can be sure that all units in the spare part store are in order.
(ii) Exchanging the Electrical Part
Remove the 4 screws for cover 2. Disconnect the two centering springs 52 from the control
fork. Remove the two fixing screws for the electrical part. Lift the electrical part off the servo-
valve. Assembly in the reverse order.
If the electrical part must be replaced during operation, the procedure is as follows. Set control
loop on " Hand ", so that actuator is locked. Replace electrical part of servo-valve by a new
one. Release blocking unit by hand. Check whether actuator remains in a mid-position. If
necessary, set control fork according to 2, ii.
(iii) Dismantling the Hydraulic Part
The dismantling of the servo valve may also be carried out during operation, provided that the
valve is either closed or blocked (control loop to be put on " Manual "). If several valves are
connected to one oil supply system, care must be taken that the pressure-oil supply only to the
particular servo-valve is closed off. The oil supply system remains in normal operation.
(a) To be able to work on the hydraulic section of the Servo valve, the electrical part
must first be removed (Sec. (ii) above). With the R6d type the gaskets 63.66 or 61
must be handled carefully.
(b) Remove the four securing screws on Diaphragm retainer plate 45 of the hydraulic
servo valve.
(c) Withdraw control fork 44 with pivot-pin support 40, plate 45 and diaphragm 39 (R6
only).
(d) Now check step-by-step whether the defect lies with the filter 20 or with the small
orifices in the filter carriers 17 or in the spool 13.
(e) Remove the two lateral covers 30. Leave spool 13 in mid position. Carefully supply
pressure oil to the spool.
WARNING : After any part in the oil system has been opened, the pressure cock must be
opened very carefully, allowing the rise in pressure to take place slowly to
prevent any damage occurring.

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(f) The some amount of (pilot control) oil must now flow from the openings.
Experience has shown that with a clean filter and clean orifices in the filter carriers
the oil flows in a continuous stream from the servo-valve. Under normal operating
temperature of the oil the length of this stream is approx. 25 cm ; after that drops are
formed.
If the oil flow is sufficient and the same on both sides, i.e. in order, then the checking
of the servo valve may be continued ; otherwise, filter 20 and filter carriers 17 must
be checked as described below.
(g) Filter and filter retainers
Only when it is found that it is through these parts that the flow is insufficient or
is in fact blocked, are these parts to be removed. An indication that the oil
throughout was insufficient would, for instance, also have been given by the fact
that the actuator was fairly sluggish in both directions when operated on " Manual
", i.e. it would have reacted only after a few seconds ; this, of course, under normal
oil temperature. Loosen screws 16 so that it is possible to withdraw the filter
retainers 17 together with O-rings 18 and 19 and filter 20. Normally a dirty filter
should not be reused; only if a replacement is not available should it be washed in
the cleanser fluid and then blown through with clean compressed air (air direction
opposite to the oil flow direction).
The filter retainers should be washed in a cleansing fluid and the orifices checked
with a steel wire of 0.1 mm diameter, to ensure that the holes are clear. After all
parts have been cleaned and installed again, the above test should be repeated, to
be on the safe side. When the filter is again assembled, care must be taken that it
is not damaged, so that no ceramic splinters can enter the oil system. Only when it
is certain that the oil flow is sufficient, should the test on the servo valve be
continued.
(h) Spool
The spoof 13 can be removed from one side only, which is marked with a green
spot.The spool itself is also marked on this side, a cross having been burnt with
the electro-graph on to the first shaft groove.
The spool should be withdrawn with a small threaded rod, the thread of which
must be absolutely clean for this purpose. The spool should be washed in a
cleanning fluid and in addition the orifices are to be cleaned with a steel wire of
0.2 mm dia. Immediately before reassembling, the cleansing fluid should be blown
through the spool, whereby the liquid must squirt out of both orifices.
NOTE : Use preferably perchlorethylene or petrol (gasoline) as cleansing fluid
(trichlorethylene in extreme).
WARNING : These cleansing liquids are inflammable and toxic.
The working site or workroom must be well aired
(i) All rubber parts must be removed before cleaning, since they will swell shortly
after having been in contact with the cleansing liquid. They can be cleaned in clean
oil.
- The diaphragm 39 (for R6 only) should be removed only for replacement Loosen
the four screws for the bushing 48. Next the nut 38 of the locking ring 46 must be
released and both parts removed.

6
Index
 released and both parts removed.
The diaphragm 39 can now be taken out.
- Dismantle pivot pin 49, support 40 or 45 and fork bushing 41 only if there is any
play between these parts and the control fork 44.
(iv) Re-Assembly
The assembly is carried out in the reverse sequence to the dismantling
(a) If old diaphragm was removed, replace with a new one. Tighten spacer 46 with nut
38, and then screw bushing 48 to retainer plate.
(b) When assembling spool with the spool bushing this must be wetted with clean oil.
Introduce spool 13 in the proper position into the spool casing and turn in such a way that the
two small holes, which are afterwards covered by the fork, are visible from the front. Fit the
two pin guides and emergency levers 30.
Open pressure oil supply to this servo valve. The oil ought now to squirt with equal force out
of the two small holes.
(c) The spool must now be turned in such a way that the small holes are in the proper
position (see Section V-V), allowing the control fork together with retainer plate to
be introduced.
Fasten blocking flange 45 to spool casing 15.
(d) The electrical part of the servo-valve must now be fitted.

7
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 8
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 9
Index
SERVO VALVE ST 10-63/R6 TYPE 6771-. (PARTS LIST)
1 Push button
2 Electric-element cover
3 Electric-element casing
4 End plate
5 Upper pole piece
6 Coil
7 Coil bobbin
8 Coil body
9 Permanent magnet
10 Square block
11 Bottom plate
12 Base plate
13 Spool
14 Spool housing
15 Housing
16 Screwed insert
*17 Filter holder
*18 O-ring 14 X 1.78
*19 O-ring 6.07 X 1.78
*20 ceramic filter
21 Return spring
22 Spring retaining ring
23 End plate (plug side)
24 Name plate
25 Plug socket
26 Lever
*27 O-ring 9.25 X 1.78
28 Push pin
*29 O-ring 2.54 X 1.78
30 Spool housing end cover
31 Carrier plate
32 Distance piece
33 Ball bearing
34 Armature
35 Bearing carrier
36 Side plate
10
Index
 37 Armature support
38 Nut
*39 Diaphragm
40 Fork pivot pin support
41 Pivot pin bush
42 Side plate
43 Indication plate Open/Close
44 Control fork
45 Diaphragm retainer plate
46 Spacer
*47 O-Ring 26.69 x 1.78
48 Pivot housing
49 Fork pivot pin
*50 O-Ring 13.99 x 1.78
51 Union
52 Centring spring
53 Frame
54 Adjusting screw
55 Locking screw
56 Soft locking pin
a,b DC voltage from controller
c Earth
L Leakage oil
Lb Leakage oil from Blocking unit
P Pressure oil
Pb Pressure oil to Blocking Unit
St Control oil
T Drainage oil
Vst Pilot control oil
SW Spanner size across flats (AF) in mm
* Spares
When ordering spare parts, please quote Type No. and part number e.g. 6771/20
SERVO-VALVE ST 10-4/R6 TYPE 6770-(PARTS LIST)
1 Push button
2 Electric -element cover
3 Electric -element casing

11
Index
 4 End plate
5 Upper pole piece
6 Coil
7 Coil bobbin
8 Coil body
9 Permanent magnet
10 Square block
11 Bottom plate
12 Base plate
13 Spool
14 Spool housing
15 Housing
16 Screwed insert
*17 Filter holder
*18 O-ring14 X 1.78
*19 O-Ring 6.07 X 1.78
*20 Ceramic Filter
21 Return spring
22 Spring retaining ring
23 End plate (plug side)
24 Name plate
25 Plug socket
26 Lever
27 O-Ring 9.25 X 1.78
28 Push pin
29 O-ring 2.54 X 1.78
30 Spool housing end cover
31 Carrier plate
32 Distance piece
33 Ball bearing
34 Armature
35 Bearing carrier
36 Side plate
37 Armature support
38 Nut
*39 Diaphragm

12
Index
 40 Fork pivot pin support
41 Pivot pin bush
42 Indication plate Open/Close
43 Side plate
44 Control fork
45 Diaphragm retainer plate
46 Spacer
*47 O-ring 26.69 X 1.78
48 Pivot housing
49 Fork pivot pin
*50 O-ring 13.99 X 1.78
51 Union
52 Centring spring
53 Frame
54 Adjusting screw
55 Locking screw
56 Soft locking pin
ab DC voltage from controller
c Earth
L Leakage oil
Lb Leakage oil frorn Blocking Unit
P Pressure oil
Pb Pressure oil to Blocking Unit
T Drainage oil
St Control oil
Vst Pilot control oil
SW Spanner size across flats (AF) in mm
*Spares

When ordering spare parts, please quote Type No. and part number, e.g. 6770/20

SERVO-VALVE ST 10-4 R 6 Z (PARTS LIST)

4 Housing
5 Pole piece
6 Coil
7 Coil body
8 Coil support
13
Index
9 Permanent magnet
 14
Index
 12 Base plate
13 Spool
14 Spool housing
15 Housing
16 Filter holder screw
* 17 FiIter holder
*18 O-Ring 14 x 1.78
* 19 O-Ring 6.07 x 1.78
* 20 Filter
25 Wall mounting receptacle with Pan-Head screws and gasket
25 a Plug
26 Control lever (Manual control)
* 27 O-Ring 9.25 x 1.78
28 Control pin
* 29 O-Ring 2.90 x 1.78
30 Cover
31 Carrier plate
32 Distance piece
33 Ball bearing
34 Armature
35 Bearing flange
37 Armature support
38 Nut
*39 Diaphragm
40 Fork pivot pin support
41 Pivot pin bush
43 Indication plate Open Close
44 Control fork
45 Flange
46 Clamping ring
47 O-ring 26.69 X 1.78
48 Bushing
49 Fork pivot pin
50 O-Ring 13.99 x 1.78
51 Connection EO GE 12-SM
53 Frame

15
Index
57 Throttling screw
58 Centering spring
59 Cover
60 Gasket 73 x 124 x 1.5
61 Screw with spring washer
62 O-Ring 24.99 x 3.53
63 Terminal cap
64 Clamping bar
65 Screw
66 Gasket 63 x 118 x 1.5
1,2 DC voltage from controller
3 Earth
L Leakage oil
Lb Leakage oil from Blocking Unit
Ma Torque in Nm (1 Nm = 0,102 mkp)
p Pressure oil
Pb Pressure oil to Blocking Unit
St 1 &2 Control oil
SW Width across flats (AF) in mm
T Return oil to tank
VSt 1 &2 Pilot control oil
*SPARES
When ordering spare parts, please quote code sheet and part number,
e.g.: 86211/66
The position (fixing)has to be adapted to the local conditions.

16

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 17
Index
 18
Index
 19
Index
 20
Index
 21
Index
 22
Index
INSTRUCTIONS FOR THE ASSEMBLY OF DIAPHRAGAM

23
Index
INSTRUCTIONS FOR THE ASSEMBLY OF CONTROL FORK
WITH SPOOL

24
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Index
Index
Index
BLOCKING UNIT

Bharat Heavy Electricals Limited

Tiruchirapalli

PUB. NO. 7112

Index
 CONTENTS

INTRODUCTION

GENERAL

APPLICATION AND DESCRIPTION

FUNCTION

RELEASE

BLOCKING

ELECTRICAL BLOCKING (DE-ENERGISED SOLENOID)

HYDRAULIC BLOCKING

MOVEMENT OF BLOCKED ACTUATOR

MANUAL OPERATION (DE-BLOCKING BY HAND)

FUNCTIONAL CHECK

BLOCKING UNIT-PARTS LIST

Index
1. INTRODUCTION

(i) General
The blocking unit is part of the electro-hydraulic actuating system, situated in the oil circuit
between the servo-valve and the actuator (see also " Electro-Hydraulic System " diagram).
(ii) Application and Description
The blocking unit has the function of freezing the actuator, and the valve, in its last held
position.
In addition 2 different arrangements of the solenoid and the manual de-blocking lever have
been used.
The main parts of the blocking unit are the housing with spool and guide bush, spring, and the
magnet solenoid.
According to the control system used the solenoid is suitable for DC.

2. FUNCTION

(i) Release
When the magnet is energised the spool of the pilot valve opens the connection from the
pressure chamber to the blocking spool 17 compressing the spring 15 at the same time. This
in the normal operating position, allowing free movement of the oil to and from the actuator
cylinder, i.e. the blocking element is released.
(ii) Blocking
The blocking spool 17 is returned to its original position by the pressure of the spring 15 and
so interrupts the connection of Stl and St2 to Stl' and St2'. The actuator is immediately frozen
in its last held position.
(a) Electrical Blocking (de-energised solenoid)
The de-energising of the coil, and therefore the blocking action, is the result of any of the
following

- Selecting the controller into " Manual

- Low oil-pressure trip from relevant micro-switch on oil supply unit pressurestat.
- Failure of the electrical supply.
(b) Hydraulic Blocking
Should the oil pressure P on the blocking spool drop below the return pressure exerted by the
spring blocking will result.
(c) Movement of Blocked Actuator
The internal parts of the blocking unit are machined to very close tolerances, so that the
blocked actuator can be held accurately in place. With actuator and blocking unit in perfect
condition, the maximum creep of the largest actuator (ASM 250) should not exceed 2 mm in
30 minutes. Creep may be on higher side for small size actuators depending upon the size of
the actuator.

Index
 (d) Manual Operation (de-blocking by hand)
If the oil pressure is sufficiently high, the actuator can be moved as follows.
- Blocking unit without possibility of direct mechanical de-blocking (magnetic valve
vertical)
Push the button Sch to move the pilot valve spool to the end position, so that the pressure oil
P can flow through the magnetic valve and move the spool 17 into its operational position.
The connections between Stl and St2 with Stl' and St2' are then remade. By simultaneous
pressing of one of the buttons of the servovalve, the actuator and the valve itself, can then be
moved in either direction.
- Blocking unit with lever for direct mechanical de-blocking (magnetic valve horizontal)
By moving the lever at the side upwards, the spool 17 is moved into its operational position.
Then proceed as above.
(e) Functional Check
Following maintenance, or a change of oil, the electrical and hydraulic blocking functions of
the blocking unit are to be checked carefully.

BLOCKING UNIT BL 10 (PARTS LIST)

1 Screw with spring washer
*2 O-ring 7. 0 x 1. 5
*3 3/2-Way directional control valve Rexroth, typ 4 WE 6 N /G 48 Z 5
4 Screw with spring washer
*5 O-ring 14. 0 x 1. 78
*6 O-ring 2. 9 x 1. 78
7 Pin
8 Deblocking lever
9 Cover
10 Piston
* 11 O-ring 6. 07 x 1. 78
* 12 O-ring 17. 12 x 2. 62
* 13 O-ring 31.47 x 1. 78
14 Spring centering disc
15 Pressure spring 3.2 x 23 x 61
16 Spring housing
17 Piston
18 Spool guide bush
19 Spool housing
* 20 O ring 7.65 x 1.78
21 Connection plate

Index
A, B Control oil to / from Servovalve
A', 'B' Control oil to / from Hydraulic Actuator
L Leakage oil
P Pressure oil to solenoid valve
X Pressure oil to Blocking Unit
a Torque in Nm (1 Nm = 0, 102 mkp)
SW Width across flats (AF) in mm
* SPARES
When ordering spare parts, please quote code sheet and part number
e. g.: 86-250/10

Index
 6

Index
BLOCKING UNIT B L 10 - TYPE 6760

Index
Index
Index
Index
Index