Overhaul Manual

Vickers

Directional Controls

Directional Control Valves

DG3V-8/DG5V-8 Hydraulic/Solenoid Pilot Operated

5007.00/EN/1099/M

Contents

Section I. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Model Code Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Section II. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Section III. Valve Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Section IV. Pilot Valve Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Section V. Internal Valve Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Section VI. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Section VII. Service, Inspection & Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Section VIII. Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 DG5V-8-S/H-*(C)-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 DG3V-8-*(D) (2/8 / 28)-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 DG4V-3(S)-*A(L)/B(L)-FJ/FW-60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Section IX. Internal Body Passages & Plug Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Section X. Start-Up and Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Eaton Hydraulics, Incorporated 2000

All Rights Reserved

Section I. - Introduction
A. Purpose of Manual
This manual describes operational characteristics, maintenance requirements, and overhaul information for Vickers DG3V-8 and DG5V-8 series single stage and two stage pilot operated and hydraulic operated directional valves. The information contained herein pertains to the latest design series as listed in Table 1.

C. Model Codes
Variations within each basic model series are covered in the model code. See Table 2. Each unit has a model code marked on the main stage nameplate. Service inquiries should always include the complete model number as noted on the nameplate. Model Description DG3V-8*A DG3V-8*C DG3V-8*D DG5V-8*A DG5V-8*B DG5V-8*C DG5V-8*D DG5V-8*F DG5V-8*N Table 1. Related Publications 5007.04/EN/0496/S 5007 04/EN/0496/S 5007.02/EN/0196/A 5007.03/EN/0496/S Application Drawing Parts Drawing

B. Related Publications
Service parts and installation dimensions are not contained in this manual. The parts and installation drawings listed in Table 1 are available from any Vickers sales engineering office

Model Code

10

11

12

13

14

15

Special Seals

Spool/Spring Arrangement Spring offset to A port Spring centered with solenoid A removed Spring centered Pressure centered Spring offset to A port, shift to center Nospring detented (pilot valve only) Left Hand Build

12

Spool Control Modifications

(Omit if not required) F3 - Seals for fire resistant fluids F6 - Seals for water glycol
2

ABCDFN-

Directional Control Valve

DG5V - Subplate mounting; solenoid controlled; pilot operated. Pressure rating 350 bar (5000 psi) for all ports.
3

Valve Size
9

8 - Valve size CETOP 8, NFPA D08

4

Pilot Valve Type

L - Single solenoid models only, omit if not required.

10

H - CETOP 3 High performance S - CETOP 3 Standard performance

5

Manual Override Options

(Omit if not required) 1 - Stroke adjustment (both ends) ( not available on D models) 2 - Pilot choke adjustment (available on all models) 3 - Pilot choke and stroke adjustments (both ends) (available on D models) 7 - Stroke adjusters on A port end only ( not available on D models) 8 - Stroke adjusters on B port end only (available on all models) 27 - 2 and 7 combined (not available on D models) 28 - 2 and 8 combined (available on al models)
13

CETOP 3 piloted models only, omit if not required. Blank - Plain override in solenoid ends (Omit if not required) only WARNING H - Waterproof override in solenoid ends only When the standard performance H2- Waterproof override in both ends of pilot is selected, the reducer single solenoid module is required to limit high P2 - Plain override in both ends of single drain line pressure transients generated solenoid during shifting. Y - Lockable manual override in solenoid ends only (DC models 6 Gauge Ports only) Blank - .4375-20 UNF-2B Thread Z - No override in either end 1/ BSP Thread B- 4 Reducer Module
7

External Pilot Pressure

E -External pilot pressure. Omit for internal pilot pressure models.

14

Internal Pilot Drain

T - Internal pilot drain to T port. Omit for external pilot drain models.
15

Check Valve in Pressure Port

Spool Types

11

Fast Response

Omit if not required. K - 0,3 bar (5 psi) check Q - 2,5 bar (35 psi) check R - 3,5 bar (50 psi) check S - 5,0 bar (75 psi) check

0 - Open to T all ports 1 - Open P&A to T, closed B 2 - Closed to T all ports 3 - Closed P&B, open A to T 4 - Tandem P to T, closed crossover 6 - Closed P only, open A&B to T 7 - Open P to A&B, closed T 8 - Tandem P to T, open crossover 9 - Open to T all ports over tapers 11 - Open P&B to T, closed A 31 - Closed P&A, open B to T 33 - Closed P, open A&B to T over tapers 52 - Closed center, regen. by sol. A 521 - Closed center, regen. by sol. B

X - Not available for pilot pressures above 210 bar (3000 psi).(Omit for standard internal pilot pressure models)

Model Code (continued)

16

17

18

19

20

21 22

23

24

25

26

27

28

16

Solenoid Energization Identity

19

Coil Type

22

Electrical Options

Blank - Standard arrangement for ANSI B93.9 (i.e. energize solenoid A to follow flow P to A). V - Solenoid identification determined by position of solenoid (i.e. solenoid A at port A end/solenoid B at port B end). Note 4 and 8 type spools are always V. Solenoid energization identity is independent of mainstage porting.
17

Heading Electrical Flag Symbol

M - Features and options for pilot valve.

18

Pilot Valve Monitoring Switch

F - Flying lead (required for wiring housing option) KU - Top exit flying lead P - Plug in SP1- Single 6.3mm spade SP2- Dual 6.3mm spade U - ISO 4400 (DIN 43650) X1 - Flameproof solenoids BASEEFA/CENELEC (S piloted models only) X2 - Explosion proof solenoids CSA/UL (S piloted models only) X3 - Explosion proof solenoids BASEEFA ExS (S piloted models only)
20

(Omit if not required) U-type coils only 1- Fitted connector 2- Fitted connector and variable grommet 6- Fitted connector with lights
23

Solenoid Indicator Lights

(Omit if not required)

24

Surge Suppressor/Damper

(Omit if not required) S3- Limit switch normally open, wired to electrical connector with AC w/PA5 (H piloted models only) S4- Limit switch normally closed, wired to electrical connector with AC w//PA5 (H piloted models only) S5- Limit switch - unwired (H piloted models only) S6- Position switch with DC w/U coils (H piloted models only)

Electrical Connections

(DC voltages only, omit if not required) D1- Encapsulated diode (industrial applications) D2- Encapsulated diode (mobile applications) D7- Encapsulated transzorb
25

(F type coils only, omit if not required) PA - Instaplug, male receptacle only PB - Instaplug, male and female receptacle PA3- 3pin connector PA5- 5pin connector T - Wired terminal block (wiring housing option also required)
21

Coil Voltage Identification Letter

26

Pilot Valve Port Orifices

(Omit if not required)

27

Design Number Special Modifications

Wiring Housing
28

W - 1/2 NPT threaded connection J - 20mm threaded connection G - 1/2 BSPP threaded connection

(Omit if not required)

Section II. - Description

A. General
Directional valves are devices used to change the flow direction of fluid within a hydraulic circuit. A valve is designed to control the direction of movement of a work cylinder or the direction of rotation of a fluid motor.

B. Basic Four-Way Sliding Spool Directional Valve Construction

Vickers valve bodies have a precision machined bore in which a very close tolerance spool is suspended on a film of hydraulic fluid. Spool lands and body cavities are designed to divide the bore openings into separate chambers. Ports in the body lead into these chambers so that spool position determines which ports are open or closed. See Figure 1. Oil flow is directed from one port to another within the body and out of a port to the work

C. Two Stage Directional Valve Construction

Two stage directional valves are pilot pressure operated. A two stage valve is constructed by combining a pilot valve and a larger main stage valve into one assembly. A DG4V-3(S) pilot valve is mounted on top of the main stage valve. When a pilot valve solenoid is energized (activated), the pilot spool moves and fluid is diverted to the mainstage; thus controlling main stage spool movement. Figure 2 illustrates the basic construction of a two stage, pilot operated directional valve.

Figure 1. Spool Type Four-Way Valve

Figure 2. Typical DG5 Type Solenoid Controlled, Pilot Operated Valve

Section III. - Valve Operation

A. General
Directional valve operation is determined by four factors: spool type, spool positioning, method of control, and special features. Proper selection of the above factors establish and regulate desired flow paths through the internal ports of the valve. The following information discusses those factors with respect to valve operation. B. Type 1 spool is designed with ports (P), (A) and (T) interconnected. Port (B) is blocked in center position.

B. Spool Types - Main Stage Section

Operation of spools are governed by their design as well as the means of control. The most common designs are open center, closed center and tandem. During the following discussion, basic spool design is related to valve port openings, with the spool in center position. Port openings are stated as: P-Pressure Port, A&B-Actuator Ports, and T-Tank or Reservoir Port. 1. Open Center Spools (0, 1, 9 and 11 types): Open center valves are used in single operations where no other operation is performed by the same source of power and where cylinders do not have to be held by pressure. Open center spools are also used to minimize shock in a system. Shock develops when a valve spool is shifted from one position to another across center position. The smoothest possible minimum shock condition is obtained when fluid under pressure is allowed to discharge to tank as the spool passes center condition. Open center with (A) or (B) ports blocked. A spool of this type is generally used to operate a cylinder. When the spool is centered, a cylinder port is blocked and the cylinder is held in a definite position. In some circuits, flow from the tank port is piped into the pressure port of another valve. This allows the same source of power to operate two different cylinders. This type of arrangement may be used in a system containing a number of operations. However, each operation must be performed in a certain sequence, with only one operation taking place at any one time. A. Type 0 spool is designed with ports (P), (B), (A) and (T) interconnected when the spool is in center position.These ports are momentarily interconnected during spool crossover when the pilot valve solenoid is activated. This permits smooth rapid cycle operation. A B P T

B Closed - Pressure Open to Tank through A

C. Type 9 spool is similar to type 0 spool except all ports are partially open in center position.

A B )( )( )( )( P T

Open Center, Partial, All Ports

D. Type 11 spool is a type 1 spool reversed in the bore. The type 11 spool interconnects (P), (B) and (T) in center position with (A) blocked.

A B P T A Closed, Pressure Open to Tank through B

AB Open Center PT

2. Closed Center Spools (2, 3, 6, 31, 33, 52 and 521 types): Closed center spools are used where two or more operations are performed by a single pump or an accumulator. Closed center valves prevent the loss of fluid from the pump or accumulator when the spool crosses center. A. Type 2 spool blocks ports (P), (A), (B) and (T) from one another in the center position. The ports are momentarily blocked during spool crossover.

D. Type 31 spool is a type 3 spool reversed in the bore. A type 31 spool is interconnected at ports (B) and (T), but blocked at ports (P) and (A) in the center position.

A B P T
T A P B

Pressure and A Closed - B Open to Tank

A B P T

Closed Center - All Ports Closed

E. Type 33 spool provides controlled leakage from port (A) and (B) to port (T). Port (P) is blocked in the center position.

B. Type 3 spool is designed with ports (A) and (T) interconnected and ports (P) and (B) blocked in the center position.
T A P B

A B )( )( P
T A P B

Closed Center - Bleed A & B

F. Type 52 spool

A B P T

Pressure and B Closed A Open to Tank

C. Type 6 spool is interconnected at ports (A), (B) and (T). Port (P) is blocked in the center position. A B

Closed Center, Regen. by Solenoid A P T G. Type 521 spool

T A P B

A B Pressure Closed A & B Open to Tank P T

T A P B

A B P T

Closed Center, Regen. by Solenoid B

3. Tandem spools (4 and 8 types): Tandem spool valves are used in hydraulic circuits where two or more hydraulic cylinders or motors are controlled from a single source of power. The valves spool is designed so that in center position, all cylinder connections are blocked and full pump delivery is connected to tank. The tank connection of one valve may be connected to the pressure connection of another valve and both valves operated simultaneously as long a the combined pressures developed by the two loads are within the capabilities of the power source. A. Type 4 spool allows oil to circulate freely from port (P) to port (T) in the center position. Ports (A) and (B) are blocked to the workload.

D. Main Stage Spool Position

Main stage spools are positioned within the valve by special arrangements. The four basic main stage positioning arrangements are: no spring-floating, spring centered, spring offset and pressure centered. The following paragraphs (1 through 4) describe these arrangements. A fifth function can be obtained by the use of a detent pilot valve. This function is described in paragraph five. 1. No Spring-Floating: When centering springs are omitted from the main stage spool, the spool is said to be floating. If control pressure is removed, a floating spool can move from its last position under the influence of gravity or tank line pressure. This must be considered during the design of the system. Units with floating type spools have the model code letter omitted. Figure 3 illustrates floating spool positioning in a two-stage valve.

A B P T Closed Crossover, Pressure to T with A & B Blocked

A
BPA

B. Type 8 spool is designed similar to type 4 spool. Ports (P) and (T) are connected in the center position. However, ports (A) and (B) are momentarily open during spool crossover.

1. Solenoid A is energized and shifts pilot spool to the right. This opens pressure to pilot port A and the main stage spool. 2. When solenoid A is energized, the main stage spool will shift left. Flow from PA and BT is obtained.
T A P B

A B P T

Tandem, Open Crossover, Pressure to T with A & B Blocked

3. Main stage spool will stay in this position until solenoid B is energized, but may float to other positions with both solenoids de-energized. Figure 3. No Springs, Floating Model

C. Methods of Spool Control, Main Stage

1. Remote Pilot Source: Main stage valves are available for use with a remote source. This means that the valve is shifted from a remote pressure source by other valves in the logic circuit. 2. Integral Pilot Valve: The integral pilot type two stage valve is a very common valve used in the field today. Two stage valves allow large volumes of fluid to be switched to and from an actuator with minimum power required for control. Reference figures 3 through 7 shown in the following section.

2. Spring Centered: A spring and washer arrangement is used on both ends of the main stage spool in the spring centered configuration. If control pressure is removed from a spring centered spool, the valve will go to the center position due to spring force. Two configurations of a two-stage spring centered valve can be obtained, a type B and a type C. If one solenoid is used on a spring centered pilot valve, the model code is identified with the letter B. When two solenoids are used, the model code is identified with the letter C. Figure 4 illustrates spool positioning of a two-stage spring centered C model.

3. Spring Offset: Single stage spring offset models use one spring to return the spool to an offset position. In two-stage models, the spring and washer is removed from the main stage and offset action is obtained from the pilot valve. Spring offset pilots control the main stage when the solenoid is de-energized, through spring action, so long as pilot pressure is available. Spring offset valves have the letter A stamped into the nameplate. Figure 5 illustrates an offset two-stage valve. 4. Pressure Centered: Pressure centered valves provide more positive centering arrangement than normal spring centered valves. This is accomplished in the following manner: Assume both pilot valve solenoids are de-energized and the main stage spool is positioned to the left (see Figure 6). Pilot pressure is applied to both ends of the main stage from the number seven (7) pilot spool. The sleeve moves to the right under the influence of the spring and pilot pressure until the position shoulder is contacted. Since the sleeve and piston areas are greater than the total spool area at the right hand end of the valve, the sleeve continues to move to the right carrying the piston with it until it contacts the valve body (center position). WARNING Loss of pilot pressure will not guarantee spool position. Shoulder of piston

Solenoid is de-energized

B
BP A

Main Stage The spring returns pilot spool to A offset position and shifts main stage spool. Main stage oil flow is PA and BT. T A P B T Figure 5. Spring Offset A Model

A
BPA

A
BP A

B
Main Stage Washer T Main Stage Spring Sleeve Piston 1. Solenoids are de-energized. Pilot spool is in center position. (PA & B, T blocked) (shown). 2. Pilot pressure keeps main stage spool in center position. Flow is blocked to all ports. 3. When solenoid B is energized, the pilot spool shifts to the left. Oil under pressure enters piston area causing the main stage spool to shift to the right. Main stage flow from PB and AT is obtained. Figure 6. Pressure Centered D Model If pilot pressure falls below 20 bar (300 psi), the centering springs will cause the spool to center within the valve body. Pressure centered models have the letter D stamped into the unit nameplate. Figure 6 illustrates spool/spring arrangements on pressure centered models. Note A fifth condition of the main stage spool can be obtained through the use of a detent pilot stage. Refer to the following paragraph. 10 A P B T

A P

1. Solenoids are de-energized. Pilot spool is in center position due to spring force. Flow is A & BT with P blocked. 2. Main stage springs and washers keep main stage spool at center position. When solenoid A is energized, the pilot spool will shift to the right, causing the main stage spool to shift left. Main stage flow would then be PA and BT. Figure 4. Spring Centered C Model Assume the main stage spool was positioned to the right with both pilot valve solenoids de-energized, pilot pressure is applied to the sleeve and piston areas on the left side but the sleeve is bottomed against the valve body at this time. Only the piston area applies force to the left end of the spool. Since the spool land area at the right side is greater than the piston area, the spool will be forced to the left until the piston shoulder butts against the sleeve (center position).

5. Detent Valve Operation: Detent valve operation can be achieved by installing a detent into the pilot valve. A detent is assembled on one or both ends of the pilot spool depending on the type of pilot valve used. When a pilot valve solenoid is de-energized, the detent holds the pilot spool in the last position attained and the main stage spool remains in its last position.

5 6

Main Stage Spool

7 3 Part No. 1 2 3 4 2 1 Part No. Part Name 5 Piston 6 Jamnut 7 Adjuster Screw

WARNING If pilot pressure fails or falls below the minimum requirement of 5 bar (75 psi), the main stage spool will shift to center position even though the pilot valve remains in the last detent position. For this reason, flow conditions in center or neutral position must be selected with care. Detent models are indicated by the letter N stamped into the unit nameplate. Figure 7 illustrates the spool/spring arrangement on detent models.

Part Name Cover Spring O-Ring Back-up Ring

Figure 8. Stroke Adjuster Feature 2. Pilot Choke Option (Fig. 9): A pilot choke increases the amount of time it takes to shift the main stage spool from one position to another. Increasing shift time lowers the possibility of developing large flow transients in the circuit. A pilot choke is designed to allow free flow to one end of the main stage spool but restricts flow out of the opposite end. The rate of spool travel, in either direction, can be slowed by loosening a locknut and turning an adjusting screw clockwise. To increase the rate of spool travel, turn the adjusting screws counterclockwise. When a pilot choke is used, pilot pressure should be taken from a constant pressure source. The pilot choke is mounted between the pilot valve and the main stage sections. 2 7 6 5 4 3 1

Detent

A
Pilot Solenoid B P A

T Main Stage

P B

1. Solenoid A is energized and shifts pilot spool to the right. 2. Which causes main stage spool to shift left. Oil flow from PA and BT is obtained. 11 3. Main stage spool remains in position attained due to pilot valve detent until solenoid B is energized. (Note: If pilot pressure fails, the main stage will shift to center position. Figure 7. Detented N Model 13 12 9 10 8

E. Optional Features (Main Stage)

Control of the mainstage spool travel can be modified with certain optional features. The most common features are discussed in the following paragraphs. 1. Stroke Limiter Adjustment (Fig. 8): Main stage spool travel can be limited by using stroke adjust covers. Stroke adjust covers may be used on one or both ends of the main stage section. When the stroke is limited, maximum flow through the valve is reduced (assuming same inlet pressure). This slows the actuator movement.To limit the spool travel, loosen the jam nut and turn adjusting screw clockwise. Part No. 1 2 3 4 5 6 7

14 Part Name Part No. Retaining Ring 8 Nut 9 Adjusting Screw 10 O Ring 11 Back-up Ring 12 Needle Housing 13 O Ring 14 Figure 9. Pilot Choke 11 Part Name Back-up Ring Needle Spring Sleeve Body Dowel Pin O Ring

3. Reducer Module (Fig 10): The reducer module is required for piloted models when pilot pressure exceeds 210 bar (3000 psi). These two-stage spool valves maintain a reduced outlet pressure against variations in inlet pressure. These valves are able to act as relief valves (at 50% of the maximum flow) to prevent excess pressure being developed when an actuator is subject to a reactive load. 4. Fast Response Option: Some applications require the main stage spool to shift at a faster than normal rate. For such applications, the fast response option is used. This option requires the removal of an orifice plug within the main stage body. When the orifice plug is removed, larger volumes of fluid will enter the pilot valve section. When the pilot valve shifts, the main stage spool responds at a faster rate. However, this also generates transients that increase system shock. For this reason, the fast response option is not recommended when pilot pressures exceed 210 bar (3000 psi). Fast response models have the letter X stamped into the unit nameplate (i.e. DG5V8-**X-**-M-**-10). Refer to catalog 5007.02/EN/0196/A for response time data. Figures 20 and 21 show the location of the orifice plugs that must be removed for the fast response option.

1 9 8 5 6 7 17 4 3 2

10 14

12 13 15 16 Part No. 1 2 3 4 5 6 7 8 9

11

Part Name Part No. Plug 10 Back-up Ring 11 O Ring 12 O Ring 13 Spool 14 Body 15 Ball (2) 16 Spring Rest 17 Spring

Part Name Spring Rest O Ring Spring Housing O Ring Adjuster Housing Adjuster Nut Dowel Pin

Figure 10. Reducer Module

12

Section IV - Pilot Valve Section

1. Remote Pilot: Pilot valves, such as a DG4V-3, are available for use with a remote pilot source. This means that a valve can be shifted from a remote pressure source by other valves in the logic circuit. Refer to service parts drawing 5007.04/EN/0496/S. 2. Electrical Solenoid Pilot Operation: Electrical solenoids are attached to the pilot valve body. Internal push pins connect the solenoid to the pilot spool. When the magnetic field of solenoid B is energized, the solenoid armature moves the push pin and shifts the pilot spool towards solenoid A (see Figure 12a). When solenoid A is energized, the pilot spool shifts toward solenoid B (see Figure 12b). When both solenoids are de-energized, the pilot spool shifts to center position (see Figure 12c). Figure 11. DG5V8 with DG4V-3(S) Pilot

A. Spool Type - Pilot Valve Section

To maintain proper control, closed center pilot spools are normally used in two stage valves. In most cases, a number 6 type pilot spool is used. When a type 4 or 8 main stage spool is used, the letter V is inserted into the pilot valve model code.

B. Spool Positioning - Pilot Valve Section

Pilot spools are positioned within the valve by special spool arrangements. The three basic pilot valve spool arrangements are spring centered, spring offset and detents. The following paragraphs (1 through 3) describe pilot spool arrangements. 1. Spring Centered: A spring and washer are installed at each end of the pilot valve spool. The spring moves the spool until the washer contacts the end of the valve body. In the deenergized condition of the pilot valve, the spool is held in center position within the body by the springs and washers. 2. Spring Offset: Spring offset models use one spring and washer to return the pilot valve spool to an offset position. In this model, a solenoid is completely removed from the spring end of the pilot valve. 3. Detents: A detent mechanism is installed on one or both ends of the pilot valve spool. Detent valve solenoids can be momentarily energized to the correct position and then power may be removed from the solenoid. The detent(s) hold the pilot spool in the last position attained until the opposite solenoid is energized.

Figure 12a. Flow Conditions Pressure to B - A to Tank

Figure 12b. Flow Conditions Pressure to A - B to Tank

C. Methods of Control - Pilot Valve

The following pilot control methods are available for pilot spool position. Control Electrical Solenoid Model Codes DG4V-3, DG4V-3S

Figure 12c. Flow Conditions Flow Blocked (Center Condition #2 Spool)

CAUTION DO NOT energize both (AC) solenoids simultaneously. Sustained operation with both solenoids energized will cause excessive current in the coil and accelerates burnout.

13

A. Electrical Solenoid Types Available: Two basic types of electrical solenoids exist:Standard and high performance. The unit nameplate identifies the type of solenoid being used. See the model code in Table 2. B. Electrical Solenoid Voltage Requirement: Electrical solenoids are available in various AC and DC voltage ranges. The standard voltage and frequency range is 115V AC, 60 Hz. Refer to parts and service drawings for units with non-standard voltage ranges.Ten (-10) design units use an identification letter for the coil voltage and frequency. C. Electrical Solenoid Ground Connections and Wiring Housing: An electrical wiring housing with a 1/2 NPTF thread connection is available on DG4V-3 pilot valves. Wire grounding screws are provided for convenience. D. Manual Override: Each solenoid has a manual override plunger to shift the pilot spool. This feature allows a technician to shift the pilot spool when electricity is not available. Refer to Figure 13. To operate the manual override feature, obtain a small rod and push in on the plunger. 5. Accessories for Electrical Type Solenoids: The model code (Table 2) indicates the type of accessories used on directional valves. Obtain a parts and service drawing for your particular model (see Table 1). Most accessories pertain to the pilot section. The most common types of accessories are discussed in the following paragraphs (A through F). A. Hazardous Location Solenoids: This type of is used at locations where added protection from electrical shortage failure is mandatory, the solenoid housing is designed to completely enclose all wiring connections to the valve. Hazardous location valves are approved Class 1, Group D or Class 2, Group E-F-G, for 1various voltages. B. Monitor (Limit) Switch Feature: The monitor switch feature can be incorporate into a basic spring offset directional valve. The switch monitors valve spool position and an be wired into control circuits. This permits electrical interlocking of various hydraulic controlled motions without resorting to external mechanical arrangements. The monitor switch is a single pole, double throw contact arrangement with -normally closed and - normally open connections. Switch ratings are noted on installation drawing (Table 1). The monitor switch housing does not provide a manual plunger for operation of the switch or valve. C. Insta-Plug Connectors: Pilot valves can be supplied with electrical connectors called insta-plugs. These connectors allow quick disconnect of electrical power from the valve. The following data pertains to the insta-plug feature: PAA prefix of PA in the model code indicates the male plug section of the insta-plug feature is included on the valve.

PBA prefix of PB in the model code indicates both the male plug and female receptacle are included with the valve. the insta-plug feature is available on the DG4V-3(S) directional valves. Wiring Note Connect white wires to A solenoid and black wires to the B solenoid. Refer to parts drawing (Table 1) for additional data. D. Brad Harrison Connectors: Brad Harrison connectors thread into the 1/2 NPTF opening in the wiring housing of a DG4V-3(S) directional valve. PA3- A prefix of PA3 in the model code indicates the three pin male connector is included with the valve. PA5- A prefix of PA5 in the model code indicates the five pin male connector is included with the valve. Female Brad Harrison connectors are not available from Vickers and must be supplied by the customer. E. Solenoid Indicator Lights: Solenoid indicator lights are available for installation on the DG4V-3(S) series directional valves. Indicator lights are connected across the solenoids and will light when voltage is present at the solenoid. This gives an indication to the technician which solenoid is energized and aids in troubleshooting a system. Refer to the appropriate parts drawing for additional information.

Body Flying Lead Coil Solenoid Coil

Terminal Box Pilot Spool

Manual Override Plunger

Push Pin Wet Armature (Standard) Core Tube

Figure 13. Typical DG4V-3(S)-C-FW-60

14

Section V - Internal Valve Functions

A. General
To insure the proper application of a two stage valve, pilot pressure, pilot drain and integral check valve options must be considered. The following paragraphs (B through D) discuss these options.
Pilot Pressure (1000 PSIG) Tank Line Pressure Surge (850 PSIG) 1000 900 800 150 PSIG nP Tank Line Pressure (750 PSIG) 700 600 500 400 Note This tank line pressure subtracts from the applied pilot pressure. 300 200 100 0

B. Pilot Pressure
1. Internal Pilot Pressure (Standard): Internal pilot pressure can be obtained in two ways and must be tailored for the application. Models with closed center type spools automatically provide internal pilot pressure. Models that use open center spools require a check valve in the pressure (P) port to maintain minimum pilot pressure. In most cases, maximum internal pilot pressure is rated to 210 bar maximum (3000 PSI). Minimum pilot pressure ratings are noted in the installation drawings (see Table 1). 2. External Pilot Pressure: When pilot pressure from a separate source is used, it must be connected to the X port (external pilot pressure connection). Models that use external pilot pressure do not require a check valve at the pressure port. External pilot pressure models are identified with the letter E stamped in the unit nameplate (i.e. DG5V-8-S-2C-*-E-M-*-10). See installation drawings for maximum external pilot pressure. 3. Pilot Pressure Conversions: If it is necessary to convert your unit from external pilot pressure to internal pilot pressure or vice versa, internal plug(s) must be removed or added to the main stage body. See the figures noted in installation plug tables for internal plug locations.

Figure 14. Pilot Valve-Internal Drain 3. Drain Conversions: If it is necessary to convert your unit from external drain to internal drain or vice versa, an internal T plug must be added or removed to the main body section. Figures 21 and 22 show internal T plug locations on various models.

D. Integral Check Valves

Check valves are located within the pressure port of the main stage section. The purpose of the check valve is to develop back pressure, at the pressure port, when open center or tandem main stage spools are used. Back pressure is necessary to maintain internal pilot pressure when the main stage spool shifts to open center position. Table 3 indicates when an integral check valve is required. Pilot Pressure Source Internal Integral Check Valve Required Yes No External No Main Stage Spool Type 0, 1, 4, 8, 9, 11 2, 3, 6, 31, 33 All spools

C. Pilot Valve Drains

1. Internal Drain: Internal drain models are used when pressure surges in the tank line are small and CAN NOT overcome pilot pressure. To shift a pilot spool, pilot pressure must always exceed tank pressure by a minimum amount. Figure 14 is an example showing pilot pressure vs. tank pressure. Refer to the unit installation drawing for minimum pressure ratings. Internal pilot drain models have the letter T stamped on the unit nameplate (i.e. DG5V-8-S-2C-*-T-M-*-10). Note A 10 bar (150 PSIG) nP must always be maintained to shift closed center spools. A 5 bar (75 PSIG) nP must always be maintained to shift open center pilot spools. 2. External Drain (Standard): External drain models are recommended if pressure surges in the tank line CAN overcome pilot pressure. Drain connection Y is used for externally drained models. Pressure centered D models use two drain connections Y and W. All external drain connections MUST be piped directly to tank through surge free lines. Refer to the installation drawing (Table 1) for further information.

Table 3. Integral Check Valve Circuit Requirements Integral check valves are available at various cracking pressure ranges. The unit nameplate identifies which check valve is used (i.e. DG5V-8-S-2C-*-T-M-*-10). Refer to installation drawing (Table 1) for additional check valve information. Note As an alternate to the integral check valve, a 3.5/5 bar (50/75 PSI) check valve can be installed in the tank line of the valve to obtain pilot pressure.

15

Section VI - Installation
A. Installation Drawings
The installation drawings listed in Table 1 show installation dimensions, port locations and operating parameters. Manifold, subplate and bolt kit information is also included. Note Detent valves must be installed with the valve spool in the horizontal position for good machine reliability. The mounting position of spring offset and spring centered models is unrestricted. Note Make sure the Y drain port is piped directly to the tank. Back pressure cannot be tolerated at this valve port.

C. Piping and Tubing

1. All pipes and tubing must be thoroughly cleaned before installation. Recommended cleaning methods are sandblasting, wire brushing and pickling. 2. To minimize flow resistance and the possibility of external leakage, use only the necessary fittings and connections required for proper installation. 3. The number of bends in tubing should be kept to a minimum to prevent excessive turbulence and friction of fluid flow. Tubing must not be bent too sharply. The recommended radius for tube ends is three times the inside diameter.

D. Hydraulic Fluid Recommendations

CAUTION On solenoid operated directional valves, ensure an electrical ground is connected to the valve. This prevents the possibility of a shock hazard if a coil develops a short circuit to the frame. Hydraulic fluid within the systems performs the dual function of lubrication and transmission of power. To insure proper lubrication, system life, and component reliability, fluid selection should be made carefully with the assistance of a reputable supplier. Fluid selection should be acceptable for use with all valves, motors and pumps within the system. The fluid recommendations noted in the data sheet are based on our experience in industry as a hydraulic component supplier. Where special considerations indicate a need to depart from these recommendations, see your Vickers sales representative.

B. Fluids and Seals

Standard seals (Nitrile) can be used with petroleum, water-glycols, and water-oil emulsion type fluids. F1 seals (Butyl, EPR) must be used for alkyl phosphate-ester base fluids and aircraft type fire-resistant fluids. F1 seals cannot be used with petroleum or phosphate ester-hydrocarbon blends. F3 seals (VitonR) can be used with all commonly used industrial hydraulic fluids. VitonR is compatible with petroleum, water-base and synthetic fire-resistant fluids.
R Viton is a registered trademark of E.I. Dupont

E. Cleanliness
To ensure your hydraulic system is clean, perform the following steps: 1. Clean (flush) the entire system to remove paint, metal chips, welding shot, etc. 2. Filter each oil change to prevent introduction of contaminants. 3. Provide continuous oil filtration to remove sludge, products of wear and corrosion generated during the life of the system. 4. Provide protection to all areas that can introduce airborne contaminants into the system. 5. Perform regular servicing procedures of filters, breathers, and reservoirs.

F6 seals (Nitrile) can be used with petroleum, water-glycols, and water-oil emulsion type fluids. The following table summarizes the compatibilities of the most common phosphate ester fluids. Fluid Type Skydrol Pydraul 10-E Pydraul 29-E-L-T, 50-E 65-E, 115-E Pydraul 230-C, 312-C, 540-C Fyrquel & Fyrlube Fyrtek F1 Yes Yes Yes No Yes No F3 No No Yes Yes Yes Yes Yes F6 No No Yes Yes Yes Yes Yes

F. Overload Protection
A relief valve must be installed in the system as close to the pump as possible. the relief valve limits pressure in the system to a prescribed maximum. The setting of the relief valve depends on the work requirements of the system.

Houghton Safe 1000 Series Yes

16

Section VII - Service, Inspection & Maintenance

A. Service Tools
No special tools are required to service this valve series. NOT use a cloth to strain the fluid or lint may enter the system.

B. Inspection
Periodic inspection of the fluid condition and tube or piping connections can save time consuming breakdown and unnecessary parts replacement. the following should be checked regularly. 1. All hydraulic connections must be kept tight. A loose connection in a pressure line will permit the fluid to leak out. If the fluid level becomes so low as to uncover the inlet pipe opening in the reservoir, extensive damage to the system can result. Loose connections also permit air to be drawn into the system resulting in a noisy and/or erratic operation. 2. Clean fluid is the best insurance for long service life. Therefore, check the reservoir periodically for dirt and other contaminants. If the fluid becomes contaminated, flush the entire system and add new fluid. 3. Filter elements should also be checked periodically. A clogged filter element will cause higher pressure drops within the system. 4. Air bubbles in the reservoir can ruin the valve and other components. If bubbles are seen, locate the source of the air and seal the leak.

D. Adjustments
No periodic adjustments are required other than normal system maintenance,

E. Replacement Parts
Reliable operation throughout the specified operating range is assured only if genuine Vickers parts are used. Sophisticated design processes and material are used in the manufacture of our parts. Substitutions may result in early failure. Part numbers are shown in the parts and service drawings listed in Table 1.

F. Product Life
The service life of this product is dependent upon environment, duty cycle, operating parameters and system cleanliness. Since these parameters vary from application to application, the ultimate user must determine and establish the periodic maintenance required to maximize life and detect potential component failure.

G. Troubleshooting
Table 4 lists the common difficulties experienced with directional valves and systems. It also indicates the probable causes and remedies for each of the troubles listed. Also remember that many apparent failures may actually be the failure of other parts of the system. The cause of improper operation is best diagnosed with adequate testing equipment and a thorough understanding of the complete hydraulic system.

C. Adding Fluid to the System

When hydraulic fluid is added to replenish the system, pour it through a fine wire screen (200 mesh or finer). When applicable, pump the fluid through a 10 micron filter. DO

TROUBLE Valve spool fails to move

PROBABLE CAUSE Dirt in system Solenoids inoperative Improper assembly Improper installation connections

REMEDY Disassemble, clean and flush. Check electrical source and solenoids. Check proper assembly. Refer to appropriate figure and assembly procedure. Check installation drawings Checks parts drawing and installation drawing for proper assembly and installation connections Reverse connections to the solenoids

Valve produces undesirable response

Improper valve assembly Improper installation connections Solenoid wiring reversed

Table 4. Troubleshooting Chart

17

Section VIII - Overhaul

WARNING Before breaking a circuit connection, ensure system power is off and system pressure has been relieved. Lower all vertical cylinders, discharge accumulators and block any load whose movement could generate pressure. Plug all units and cap all lines to prevent entry of dirt into the unit or system.

C. Pilot Valve Crossover Plate Removal

1. Remove the four attaching screws (1) from the pilot valve or crossover plate (2). Remove the pilot valve from the main stage body (3). Note The following section pertains to main stage disassembly. If your unit does not require main stage disassembly, omit the following section.

A. Unit Removal
1. Thoroughly clean the exterior of the valve and the area around the valve to prevent contamination of the system during removal. 2. Remove the valve from its subplate or mounting pad as follows: A. If the valve is equipped with the insta-plug feature, loosen the two slotted screws and unplug the electrical wiring from the pilot section. B. If the valve has an air operated section, turn off air supply and disconnect the pressure lines from the connection plate.

D. General Main Stage Disassembly

(Refer to Figure 17) WARNING Spring in end cover is under tension. Slowly remove end cover screws alternatively to avoid damge to equipment and injury to personnel Note Repeat steps 1 and 2 for opposite side cover disassembly. 1. Loosen the four end cover screws (5) from end cover (6). Be ready to catch any oil trapped inside the unit. Remove the end cover and discard O ring (7). Note Spring (8) and washer (9) do not exist on spring offset A or floating type models. 2. Remove spring (8) and washer (9) from the main stage spool (10). 3. Remove main stage spool (10) from body (3). 4 Turn the body (3) on its side and remove O rings (11 and 12) and plugs (14) and (15) from mounting face. Remove plugs (16) and (17) and O Rings (18) and (19) from body (3).

WARNING In the following step make sure electrical power is off, then disconnect the solenoid wiring. Label each wire to provide assembly information. C. If the valve has standard electrically operated solenoids, remove the four nameplate screws on top of the pilot section. Move nameplate and gasket aside to expose interior of the wire cavity. Disconnect solenoid wiring. D. Loosen the six mounting screws that hold the main stage section to the mounting pad. Be ready to catch the fluid retained inside the lines and valve. E. Remove the valve from the mounting pad and set it on a clean work bench. Use a chain lift when necessary.

6. If necessary, remove rest pins (13) with vise grip pliers.

B. Disassembly (General)
The manual describes the disassembly sequence of a typical DG5V8 two-stage directional valve. See Figures 17 and 18. Slight variations may be noted on your model depending on the type of accessories and unit design. Figure 17 may be used for all models, except pressure centered D models regardless of the design. Refer to Section E and Figure 18 for pressure centered D models. Figure 19 shows the disassembly sequence of a DG4V-3(S)-*A(L)/B(L)-FJ/FW-60 standard performance pilot valve.

18

E. Pressure Centered Main Stage Disassembly

(Refer to Figure 18) 1. Remove the four attaching screws (1) from the crossover plate (2) and remove the crossover plate from the main stage body (3). Note The following section pertains to main stage disassembly. If your unit does not require main stage disassembly, omit the following section. 2. Loosen the four end cover screws (6) from end cover (7). Be ready to catch any oil trapped inside the unit. Remove the end cover, spring (10) and discard O ring (8). 3. Remove sleeve (11) and piston (12) from the main stage spool (9). 4. Remove main stage spool (9) from body (3). Note Perform step 5 for opposite side cover disassembly. Note that centering springs are different. 5. Loosen the four end cover screws (13) from end cover (14). Be ready to catch any oil trapped inside the unit. Remove the end cover, spring (15), centering washer (16) and O Ring (17). 6. Remove plug (18) and O Ring (19) from cover (7). 7. Turn the body (3) on its side and remove O rings (20, 24, 25 and 26) from mounting face. 8. If necessary, remove rest pins (27) with vise grip pliers. Note The following step pertains to integral check valve models only. DO NOT remove check valve parts unless inspection or unit operation indicates a check valve problem. If check valve removal is necessary, perform step 9. 9. See Table 7 for screw information. Obtain a piece of pipe or tubing with an inside diameter that is slightly larger than the outside diameter of the seat. Also obtain a flat washer. Remove seat (21), Figure 15, per instructions noted in Figure 15. Remove poppet (22) and spring (23). Model DG4V-3(S) Screw Dia./ Thread Type .5625-18 UNF-2B Screw Length 76.2mm (3 in.)

10. Remove O rings (4) and (29), set screw (5) and plug (28) from body (3). Screw

Washer

Tubing

Seat (21) (Figure 17) Note Thread seat (21), then place tubing and washer over seat area as shown. Thread the screw into seat (21). Tighten the screw to remove seat. Figure 15. Check Valve Seat Removal

F. High/Standard Performance Pilot Valve Disassembly (Refer to Figure 19)

Note The following steps describe the disassembly sequence of a DG4V-3(S)-*A(L)/B(L)-FJ/FW-60 pilot valve. 1. Remove the four screws (1) from name plate (2) and remove the nameplate, cover (3) and gasket (4) from the terminal box (5). Discard gasket (4). 2. Remove two screws (7) and strap (8) from the terminal box (5). 3 Remove two screws (9), ground screw (11), terminal box (5) and gasket (6) from body (10). Discard gasket (6). Note If the pilot valve is equipped with two solenoids, perform steps 3 through 6 for opposite end of body (10). 4. Remove knob (12) ) from core tube S/A (21). Remove coil (14) from body (10) and discard O Rings (13) and (15). Unscrew core tube. 5. Remove push pin (18), spring 917), washer (19) or (20) and O Ring (15) from body (10). Remove O Ring (16) from core tube S/A (21).

Table 7. Screw Tabulation for Seat Removal Note DO NOT remove the internal plugs of body unless inspection reveals a problem.

19

6. Remove pilot spool (22) from body (10). 7. Secure the body and remove plug (24) and O Ring (25) from body (10). Discard O Ring (25). 8 If necessary, remove rest pins (26) with vise grip pliers.

Note An alternate test is to turn the body on end and allow gravity to pull the spool from the body into your hand. if the spool does not move under the influence of gravity, the spool is sticking inside the body bore. If the spool binding persists, replace the valve. Check the feel of the spool. If side movement of the spool can be felt within the body bore, the body/spool clearances are excessive. A new spool and body have a select fit of approximately 0.0002-0.0003 inch. Body/spool clearances in excess of this value may still work satisfactorily in your system; however, limitations are dependant on how much leakage your valve system can tolerate. Normally, excessive body/spool clearances dictate replacing the entire valve. Note If a new spool is installed into a new or used body, break the feathered edges of the spool balancing grooves with a three or four cornered India stone. See Figure 20. Lightly polish the spool with #500 grit paper. Wash the spool in clean solvent. Repeat steps A and B. Step 6 pertains to detented N pilot valves only. 6. Check the detent by moving the spool through the detent. A steady frictional force should be observed. If the detent force is weak (less than 1 lb.), replace the detent subassembly. The detent should be assembled on both ends of the spool. 7. Perform a continuity test on each solenoid coil S/A. Resistance values will vary with the voltage rating of the coil. Refer to Table 8. This test is superficial, but a more rigorous test requires special equipment. If the coil seems to be burned or extreme heat is encountered during operation, the coil may be shorted. make sure the correct voltage is being applied to the coil. Land Balancing Grooves

H. Cleaning
All parts must be thoroughly cleaned and kept clean during inspection and assembly. Close tolerance of valve bodies and spools make this requirement critical. Clean all parts with a commercial solvent that is compatible with system fluid. Compressed air may be used to clean valve, but it must be filtered to remove water and contamination. Clean compressed air is particularly useful for cleaning spool orifices, body passages and drying parts.

I. Inspection, Repair and Replacement

1. Check that all internal passages are clean and free from obstruction. Examine all mating surfaces for nicks and burrs. Minor nicks and burrs can be removed with crocus cloth or an India stone. CAUTION DO NOT stone the edges of spool sealing lands. Remove minor burrs with #500 grit paper. Use the paper very lightly on the outer diameter of each spool. 2. Inspect all screws for evidence of damaged threads. If threads are damaged, replace the screws. 3. Inspect all springs for distortion or wear. The ends of the springs shall be square and parallel to each other. Replace springs that are damaged or distorted. 4. Check push pins, pole faces, washers, and manual plungers for burrs, cracks or mushrooming. Replace all parts that show evidence of wear. 5. Visually inspect the internal coring (bore) of each body for large scratches or erosion across the spool land sealing areas. If such evidence is found, replace valve. If the body bore passes inspection, check bore to spool clearance as follows: A. Lubricate spools and body bores with clean system fluid. make sure the parts are clean. B. Insert the spool into its body bore. Rotate the spool 360_ while moving it back and forth. Observe the following: If the spool does not move freely, the spool is sticking inside the body bore. Remove the spool and recheck the spool and body bore for scratches and/or burrs. remove any minor scratches or burrs with India stone or crocus cloth. Repeat steps A and B.

Figure 16. Spool Balancing Grooves

20

Voltage 6 DC 12 DC 24 DC 48 DC 115 DC 230 DC 115 AC (60 Hz) 230 AC (60 Hz) 460 AC (60 Hz)

Coil Resistance 1.3 Ohms 4.9 Ohms 19.6 Ohms 78.4 Ohms 412 Ohms 1680 Ohms 37 (3S) 30.5 (3) Ohms 154 (3S) 129 (3) Ohms 637 (3S) Ohms Table 8. Coil Resistance

8. Install cover (6) on body (3) with four screws (5). Torque the screws to value noted in parts drawing. Refer to Table 1. Make sure cover is oriented properly (in line with body contours). Note Repeat steps 6 through 8 for opposite side cover assembly.

L. Pressure Centered Main Stage Assembly

(Refer to Figure 18) 1. Install O rings on plugs. Lubricate plug threads and install plugs and set screws into body (3). Torque plugs to value noted in parts drawing. Refer to Table 1. 2. Tap new rest pin(s) (27) into place if removed during disassembly.

J. Assembly
Before assembly, obtain the correct seal kit as noted in the parts drawing. Lubricate all O rings and internal parts with clean system fluid to provide initial lubrication and facilitate assembly. Check the model code to determine correct assembly of units. If a L.H. suffix appears in the model code, the pilot valve solenoid is assembled left hand. Refer to service drawing for parts orientation. Assembly will be in reverse of the disassembly sequence shown in Figures 17 and 18 unless otherwise specified.

L. Check Valve Models

(Refer to Figure 18) Note The following step pertains to integral check valve models only. 3. Place spring (23) into poppet (22) and then install poppet into pressure port (P) cavity as shown. Obtain a suitable push rod and press seat (21) into pressure port (P) cavity. (See assembly drawing for seat orientation.) Use an arbor press for this operation. Install O ring (20) into pressure port mounting groove. 4. Install O ring (26) into X and Y port mounting grooves. 5. Install O rings (25) into port mounting grooves A, B and T. 6. Install O ring (24) in port mounting groove W.

K. General Main Stage Assembly (Refer to Figure 17)

1. Install O rings (18 and 19) on plugs (16 and 17). Lubricate plug threads and install plugs into body (3). Torque plugs to value noted in parts drawing. Refer to Table 1. 2. Tap new rest pin(s) (13) into place if removed during disassembly. 3. Install O ring (11) into X and Y port mounting grooves. 4. Install O rings (12) into port mounting grooves A, B, P and T. 5. Lubricate spool lands with clean system fluid and then carefully install spool (10) into main body bore. Make sure the spool moves freely inside the body bore and is oriented properly. (See parts drawing). Note Spring (8) and washer (9) do not exist on spring offset A or floating type models. 6. Install washer (9) and spring (8) on end of spool (10). 7. Install O ring (7) into body (3) as shown.

7. Lubricate spool lands with clean system fluid and then carefully install spool (9) into main body bore. Make sure the spool moves freely inside the body bore and is oriented properly. (See parts drawing). 8. Install piston (12), sleeve (11) and spring (10) into cover (7). 9. Install O ring (8) in body (3). 10. Install cover (7) on body (3) with four screws (6). Torque the screws to the value noted in parts drawing. Refer to Table 1. 11. Install O ring (17), centering washer (16) and spring (15) in body (3).

21

12. Install cover (14) on body (3) with four screws (13). Torque the screws to the value noted in parts drawing. Refer to Table 1. 13. Install plugs (18) and O rings (19) into cover (7). 14 For DG3V8 models, install crossover plate (2) on body (3) with four screws (1). Torque screws to value noted in parts drawing. Refer to Table 1.

3. Assemble washer (19) or (20) on end of spool (22) with sharp break edge toward outside of body. 4. Install spring (18), push pin (17) and O ring (15) into body (10). 5. Install O ring (16) on core tube S/A (21) and install core tube S/A into body (10). 6. Install O ring (13) on core tube S/A (20).

M. High/Standard Performance Pilot Valve Assembly (Refer to Figure 19)

1. Install O rings (25) on plugs (24). Lubricate plug threads and install into body (10). Install remaining O rings (25) into body (10). Torque plugs to the value shown in parts drawing. Refer to Table 1. 2. Lubricate pilot spool (22), then carefully install spool into the body (10). Note If pilot valve is equipped with two solenoids, repeat steps 3 through 7.

7. Install coil (14) on body (10) and secure to core tube S/A (20) with knob (12). 8. Install gasket (6) and terminal box (5) on body (10) and secure with ground screw (11) and two screws (9). 9. Install strap (8) on terminal box (5) with two screws (7). 10. Install gasket (4), cover (3) and nameplate (2) on terminal box (5) with four screws (1).

22

DG5V-8-S/H-*(C)-10

1 5 6

8 9 7 4

13 18 16 17 11 14 12 19 15 10

Item 1 2 3 4 5 6 7 8 9 10

Nomenclature Screw Pilot Valve Body Plug Screw Cover O Ring Spring Washer Spool

Quantity 4 1 1 1 8 2 2 2 2 1

Item 11 12 13 14 15 16 17 18 19

Nomenclature O Ring O Ring Pin Plug Plug Plug Plug O Ring O Ring

Quantity 2 4 2 1 1 2 8 2 8

Figure 17. Main Stage Section, Spring Centered C Model, DG5V-*-S/H*(C)-10

23

DG3V-8-*(D)-10

1 18 19 2

29 6

4 5 3 16 15 14 13

7 10 11 12 8 25 17 28 24 23 26 21 20 22 27 9

Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Nomenclature Screw Crossover Plate Body O Ring Set screw Screw Cover O Ring Spool Spring Sleeve Piston Screw Cover Spring

Quantity 4 1 1 4 1 4 1 2 2 2 1 1 4 1 1

Item 16 17 18 19 20 21 22 23 24 25 26 27 28 29

Nomenclature Centering Washer O Ring Plug O Ring O Ring Seat Poppet Spring O Ring O Ring O Ring Rest Pin Plug O Ring

Quantity 1 1 4 1 1 1 1 1 1 3 2 2 1 1

Figure 18. DG3V-8-*(D) (2/8/28)-10 Pressure Centered with Check Valve Options 24

DG4V-3(S)-*A(L)/B(L)-FJ/FW-60

1 2 3 4 7 9 8 5 6 11 19 23 7

19 14 18 10 13 12 17 16 21 24 20 15 22 25 26 20

15

Item 1 2 3 4 5 6 7 8 9 10 11 12 13

Nomenclature Screw Nameplate Cover Gasket Terminal Box Gasket Screw Strap Screw Body Screw Knob O Ring

Qty 4 1 1 1 1 1 2 1 2 1 1 1 1

Item 14 15 16 17 18 19 20 21 22 23 24 25 26

Nomenclature Coil O Ring O Ring Push Pin Spring Washer (DC models) Washer (AC models) Core Tube S/A Spool Plug Plug O Ring Pin

Qty 1 2 1 1 1 2 2 1 1 1 1 4 1

Figure 19. Standard/High Performance Pilot Valve, DG4V-3(S)-*A(L)/B(L)-FJ/FW-60

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Section IX - Internal Body Passages & Plug Locations

Two stage directional valves can be converted to different operational modes, i.e. internal/external, pilot pressure or drain, fast response, etc. To accomplish this, internal plugs must be removed or added within the main stage body passages. Table 9 is a list of basic models with the incorporated operational model changes. Each model is referenced to a particular figure. The figure illustrates internal passages and plug locations. Operational Mode Change (Reference Model Code, Table 2) *XEK/Q/R/STStandard Fast response option External pilot pressure Integral check valve Internal pilot drain CAUTION DO NOT change internal plugs within mainstage unless power is off and system pressure is relieved. Basic Model Description DG3V-8-(R)-10 DG3V-8-(R)-E-10 DG3V-8-(R)-X-10 DG3V-8-(R)-E-K/Q/R/S-10 DG3V-8-(R)-X-E-K/Q/R/S-10 DG3V-8-(R)-X-K/Q/R/S-10 DG3V-8-(R)-X-E-K/Q/R/S-10 (OmitT) DG3V-8-(R)-X-E-T-K/Q/R/S-10 DG5V-8-(R)-10 DG5V-8-(R)-E-10 DG5V-8-(R)-X-10 DG5V-8-(R)-E-K/Q/R/S-10 DG5V-8-(R)-X-E-K/Q/R/S-10 DG5V-8-(R)-X-K/Q/R/S-10 DG5V-8-(R)-X-E-K/Q/R/S-10 (Omit T) DG5V-8-(R)-X-E-T-K/Q/R/S-10 Table 9. Basic Models Plug / Orifice Installation Table DG5V-8-(R) 10 E-10 X-10 E-K/Q/R/S-10 X-E-K/Q/R/S-10 X-K/Q/R/S10 X-E-K/Q/R/S-10 (T omitted) X-E-T-K/Q/R/S-10 Out Out In In Out A Plug / Orifice Out In Out In Out In In B Plug In C Plug Ref. Plug B Plug / Orifice Installation Table DG3V-8-(R) A Plug/ Orifice In Out In Out B Plug C Plug

10 X-10 X-K/Q/R/S-10 X-K/Q/R/S10

In In In In In

Plug C

Plug A or orifice

Fig. 21

Figure 21

Fig. 21

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Section X - Start-Up and Test

A. Start-Up
Start the system and sequence the unit through all positions while watching for appropriate movement of actuators. Improper or erratic movement of the actuators may indicate incorrect assembly of the unit or presence of trapped air.

B. Test
A test stand having regulated flow, temperature control and special fixtures is required to fully test the performance of the rebuilt unit. Because of this, only the functional test shown in the start-up paragraph is given. If such a test stand is available, test the unit to the requirements set forth in the installation drawings.

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