Servovalve and Actuator Refurbishment

June, 2012
 The following pages contain proprietary information and
CONFIDENTIAL are not intended for external publication or disclosure

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granted by contract or by operation of law and is restricted to use by only Moog employees and other persons authorized in writing by Moog or as expressly granted by
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others for any purpose whatsoever except as specifically authorized in writing by Moog Inc.

©2012 Moog
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Servovalve Inspection
 Disassembled Servovalve

Torque motor parts Bushing & spool (BSA)

Typical Servovalve Refurbishment
Servovalve Refurbishment Process
Ready to Begin

Step #1 involves a visual inspection.

The Technician looks for any
evidence of external damage, loose
hardware and other obvious
abnormalities. Any findings are
recorded on the Inspection Report.
Servovalve Refurbishment Process
The Mounting Process
Next the Technician identifies the
proper mounting manifold.
He/she installs the manifold on the
test stand and mounts the
servovalve to the appropriate
manifold.
After ensuring that all the o-rings
and mounting bolts are secure
he/she then slowly increases
hydraulic pressure while diligently
looking for any external leakage.
The key here is not to get wet!
Servovalve Refurbishment Process
The Initial Testing Process

At the correct test pressure, the

Technician attempts to derive as
much pertinent valve specification
data as possible. He/she checks
polarity, internal leakage, tare flow,
flow gain and other specifications
required by the Test Worksheet.
Servovalve Refurbishment Process
The Tear Down

After the Technician has recorded all

of the valve data that could be
obtained, the next step is to tear
down the valve and inspect all
internal components for signs of
contamination, wear, tampering and
any other abnormal characteristics.
The first component inspected is the
internal filter.
The condition of the filter is noted on
the Inspection Report.
Servovalve Refurbishment Process
The Tear Down Continued!

Next, the Torque Motor is removed

and inspected.
Ball size, nozzle pressure and a
visual inspection of the nozzle/flapper
assembly are performed.
Servovalve Refurbishment Process
The Tear Down Continued!
Next, the end caps are removed and
the spool is carefully extracted. A
visual inspection is performed, looking
for wear and possible scoring.
Servovalve Refurbishment Process
The Tear Down Continued!

The bushing is then removed and

visually inspected.
Servovalve Refurbishment Process
The Tear Down Continued!

In addition, a careful visual

inspection of the body’s internal
surfaces is performed. This
observation will reveal any scoring
and possible evidence of foreign
materials such as o-ring chips or
metal particles that may be trapped
within the body cavity.
Servovalve Refurbishment Process
Parts Ordering Process
 After the Technician has completed the inspection, he/she will order any
necessary parts.
 If no parts are required, the Technician moves the valve directly to “AW”
Assembly Waiting Status. The valve is now ready to be cleaned and
reassembled.
 If parts are required, the Technician orders the appropriate components and
moves the valve to “P” Parts status.
 This is accomplished by using our on-line computer system.
 The Technician goes to a screen called “Parts Structure” and inputs the valve
model number. The system then displays a complete parts list.
 He/she then simply selects each part required by placing an “X” next to the
desired part number.
 Once all of the parts required are selected the Technician hits the accept key,
and a parts requirement list is immediately printed out in the appropriate stock
room where the components are located.
 The parts are then pulled by a clerk and delivered to the Repair Department.
 The Repair Department clerk then issues the parts to the appropriate valves
and when the kit is completed moves the valve from “P” status to “AW” status.
 The valve is now ready for the assembly process.
Servovalve Refurbishment Process
on to the assembly process …

When an Assembler is ready for

his/her next job they too access a
computer terminal and select the
next valve in line to be assembled.
The computer informs them of the
VRS location.

The Assembler then moves the

valve from “AW” status to “A”
Assembly status and retrieves the
valve from the VRS.

He/she then transports the valve to

their workstation.
Servovalve Refurbishment Process
O-ring Removal and tear-down.

The Assembler further disassembles

the valve (as required) and removes
all of the remaining o-rings in
preparation for cleaning.

Valves are cleaned in a two stage

Aqueous Cleaning System.
The first tank contains the detergent
that dissolves most of the external
dirt.

The second tank rinses away all of

detergent .
It is then dried using high pressure
air to remove all moisture.
Servovalve Refurbishment Process
Reassembling the Valve!

After cleaning, the valve is

returned to the Assembler’s
workstation for re-assembly.

With guidance from CDI’s (Control

Document Instructions) the
Assembler re-assembles the
valve.
Servovalve Refurbishment Process
Final Testing

After re-assembly your

valve is thoroughly tested to
new valve specifications.
• Flow characteristic
• Hysteresis
• Threshold
• Null bias
• Valve polarity
• Strut pressure
• Pressure null shift
• Null leakage
All repair valves are required to meet • Null shift
the same performance criteria as that
of a new valve. After all, a Moog • Null cut
repaired valve carries the same
warranty as new valve.
Servovalve Refurbishment Process

This piece of equipment is used

to plot many different
parameters necessary for proper
valve set-up. Plotters allow us
to determine Flow Gain,
Pressure Gain and Internal
Leakage. By combining a Flow
Piston, Differential Pressure
Transducer, Current Driver and
an XY Recorder we can produce
a visual picture of the dynamic
characteristics necessary for
proper valve performance.
Repair Category for J072K & J076K Series Servovalve

Category
Definitions

Category Definition
Test, flush, replace filter and base o-rings. Disassemble main
B stage if required, recalibrate and retest.

C Rebuild/replace 1st stage (Torque Motor) + Category B.

D Replace Bushing and Spool Assembly (BSA) + Category B.

E Rebuild/ Replace Torque Motor AND BSA + Category B

Typical Repair Report
Typical Repair Data Sheet
Typical Failure Analysis Report (FAR)
Typical Failure Analysis Report (FAR)
Typical Failure Analysis Report (FAR)
Typical Servoactuator Refurbishment
 Disassembled ServoActuator

Piston Rod Body Filter Element Bearings Seal Kit

Cut away drawing of Servoactuator
Actuator Testing
Actuator Testing
Actuator Testing

Every repaired actuator will be subjected to static and dynamic

testing on one of these stands.
ServoActuator Test Stand
ServoActuator Tuning
Actuator Testing

Type of Test Purpose

• Proof/Back Pressure • Pressure integrity checks
• Polarity • Servovalve functional checks
• Position Transducer Calibration • Transducer functional check
• Failsafe Test • Failsafe static and dynamic
• Loss of Electrical Signal checks
• Min Pressure • Servovalve null
• Trip Response
• Time response
 Repair Category for Servo Actuators
(Subjected to Changes)
Category
Definitions

Category Definition

Test, flush, cleaning and calibrate Actuators back to

B specification. Change all internal Seal & Filter Element.

C Class B + Add Piston Rod / Body Replating.

D Class B + Replace Bearing.

Class B + Replace Bearing and add Piston Rod / Body

E Replating.

• Excludes any servicing on any manifold, filter assembly & transmitter.

Typical Repair Report
Typical Repair Data Sheet
Typical Failure Analysis Report (FAR)
Typical Failure Analysis Report (FAR)
What makes Moog the right choice in your repair?

 Dedicated Repair Department with independent staff, test stands and

inventory.
 12 month, same as new, factory warranty.
 Only original OEM specification parts are used.
 Repair carried out at the product’s design and manufacturing facilities.
 All servovalves are rigorously subjected to various static and dynamic
tests to ensure performance meets specifications.
 Tested accordingly to Moog’s proprietary specifications.
 Closer to you – Moog offices in 25 countries worldwide with more than
100 Authorized Distributors.
 Easy access to our application engineer for consultation.
 Provide full analysis to help prolong your servovalve life and minimize
downtime.