Operator Failre

The DCV uses some type of external signal to cause it to change position. The most
common types of operators are electrical (solenoids), hydraulic (pistons), mechanical
(levers and rods), and pneumatic (pistons). The first thing to determine is if the

sticking action is occurring by something inside the hydraulic portion of the DCV or
the operator. Most valve operators have a small mechanical device called a manual

override so the mechanic can manually operate the valve. If the valve shifts when the
manual override is used but not when the normal signal is used, then more than
likely, it is an operator issue. If the valve will not shift when the manual override is

used, the problem is more than likely a hydraulic or mechanical problem inside the
DCV. A failure of the hydraulic section of the valve can cause solenoid coil burn out
which will need to be corrected when the DCV is disassembled and rebuilt.

Problem #3: High Internal Leakage/Heat

Sliding spool valves are prone to wear, especially in hydraulic systems that have high
levels of contamination. As the spool and bore wear, more pressurized fluid is lost

through these increased clearances to return to the reservoir without providing any
useful work. The energy generated by moving from high pressure to tank pressure is

released as heat. As the valve temperature increases, it will cause even more leakage.
The most common symptoms of high leakage in DCVs are slower cycle times, slower
actuator speeds, and drifting or moving of actuators when they should not be

moving. The only fix for DCVs with high leakage is complete replacement.

Problem #5: External Leakage

External leakage in DCVs is usually caused by seal failure, spool wear, pushpin wear
or a solenoid core tube failure. Seals, push pins and solenoids can be replaced but if

the seal area of an exposed manually operated spool becomes worn or damaged, it
cannot be repaired and will have to be replaced.

Conclusion
The best way to prevent Directional Control Valves from failing is to prevent system
contamination. Keeping the oil clean, cool, and dry (preventing water contamination)

will prevent most DCV failures and promote longevity of the DCVs in the hydraulic
system.