7OCEAN DSV-G02-2C-DC24-90 Solenoid Directional Valve

DSV-G02-2C-DC24-90

1. DSV: Solenoid directional valve, terminal box type solenoid

(DSD = DIN connector type; identical mounting subplate for both versions)

2. G02: Size NG6 / CETOP-03 / D03 (6 nominal diameter)
3. 2C: 4/2-way, double solenoid, spring return

Spool function: Spring return initial position; energize one solenoid → P→A, B→T; energize the other solenoid → P→B, A→T

4. DC24: Coil voltage DC24V
5. 90: Type 90 wet armature high-power solenoid

Suffix options: 20,72,82 represent different solenoid specifications. Solenoids are NOT interchangeable.

2. Core Technical Specifications

Mounting Standard: CETOP RP121H, D03 size subplate mounting

Max. Operating Pressure: 35 MPa (350 bar)

Max. Allowable Tank Back Pressure: 22 MPa

Rated Flow: ≤110 L/min

Hydraulic Fluid: Hydraulic oil (ISO VG32 / ISO VG46)

Fluid Temperature: -20 ~ +70℃

Solenoid: DC24V Type 90 wet armature solenoid, 100% continuous duty (ED100%)

Valve Weight: Approx. 2.6 kg

3. Key Distinction Points
4. DSV vs DSD-G02

DSV: External terminal box (screw wiring) – Model DSV-G02 as specified

DSD: DIN43650 quick plug connector

→ Identical internal flow path; only solenoid wiring housing differs.

2. 2C Spool Function

✅ 4/2-way double solenoid spring return; no neutral position. Valve automatically resets to initial position upon power cut.

3. Notice for Type 90 Solenoid

Strictly specify suffix -90 during procurement/replacement. Replaced by -20 series solenoid will result in insufficient actuating force, overheating and sluggish shifting.

4. Equivalent & Alternative Models
5. Original identical unit: DSV-G02-2C-DC24-90
6. Alternative wiring version: DSD-G02-2C-DC24-90 (plug type, compatible subplate)
7. Domestic compatible equivalent: WF, YUKEN DSG-01-2B2-D24 series

(Close mounting dimension; spool function verification required)

5. Typical Fault Diagnosis
6. Slow or failed shifting: Undervoltage, mismatched solenoid type, spool seizure caused by contaminated oil
7. Coil overheating & burnout: Continuous overload, voltage fluctuation, internal short circuit
8. High internal leakage: Spool wear, pressure retention failure

7OCEAN DSV-G02-2C-DC24-90 (NG6 D03 4/2-Way Double Solenoid Valve) Complete Installation Procedure

Applicable to subplate mounted hydraulic solenoid directional valve

DSV: Terminal box solenoid; DC24V Type90 high-power wet armature coil; 2C double solenoid spring return

⚠️ Operators must hold hydraulic & electrical operation qualification. Depressurize hydraulic system and cut off power before any work!

1. Pre-Installation Inspection (Mandatory)

1.1 Material Verification

Valve Model: DSV-G02-2C-DC24-90. Confirm voltage DC24V, spool code 2C, solenoid suffix 90

Accessories: Standard G02 subplate (CETOP03/D03), 4pcs M6 hex socket bolts, 4pcs O-rings for P/A/B/T port sealing

Visual check: No valve body impact, coil crack or debris blocking oil ports.

1.2 System & Environment Check

Ambient condition: -20～70℃, relative humidity＜90%RH, no condensation; Keep away from heat sources, welding spatter and heavy vibration

Hydraulic oil cleanliness: NAS 8 or superior; install ≥100 mesh filter on suction line

System maximum pressure shall not exceed 35MPa.

1.3 Tools Preparation

M6 hex socket wrench, torque wrench, lint-free cloth, dry compressed air gun, multimeter, insulated screwdriver.

2. Subplate & Valve Mounting

Step 1: Clean sealing surfaces (Critical to prevent spool sticking)

1. Blow off debris on subplate mounting surface and valve bottom sealing surface with dry compressed air
2. Wipe surfaces with lint-free cloth; eliminate iron chips, rubber fragments and residual oil
3. Fit 4 O-rings into P/A/B/T recesses on valve bottom. Avoid twisting or dislodging O-rings.

Step 2: Position and fasten valve body

1. Place solenoid valve flat on G02 subplate; align P/A/B/T ports between valve and subplate

Port Marking: P=Pressure Inlet, T=Tank Return, A/B=Actuator Working Ports

2. Insert 4 M6 bolts and screw manually to ensure full contact without tilting
3. Tighten bolts diagonally in 2~3 stages

✅ Standard tightening torque: 5.5～6.5 N·m

❌ Do NOT fully tighten single bolt sequentially. Excessive torque crushes O-rings and causes internal leakage; insufficient torque leads to high-pressure external leakage.

4. Recommended mounting posture: Horizontal installation, solenoids arranged left & right horizontally (natural layout for double solenoid). Small tilt angle permitted; long-term inverted installation is not suggested.

Step 3: Connect hydraulic piping to subplate

1. Connect hydraulic hoses to threaded ports P, T, A, B on subplate
2. Prevent external pulling force on subplate to avoid shear load and sealing leakage
3. Max. allowable back pressure on T return line ≤22MPa; keep return piping short with adequate nominal diameter.
4. Electrical Wiring (DSV Terminal Box Version, DC24V Coil)

This valve equipped with dual solenoids (left solenoid, right solenoid), DC24V, polarity sensitive!

⚠️ Perform wiring only after power is disconnected. Live wiring prohibited!

1. Unscrew terminal box cover and open enclosure
2. Each solenoid has independent terminal set:

Terminals for each coil: DC24V(+), DC24V(-); DC coil polarity must be followed

PLC/relay outputs: Two independent control signals. Simultaneous energization of left & right solenoids is strictly forbidden!

3. Use copper control cable ≥0.75mm²; securely crimp terminals; avoid loose stray wires causing short circuit
4. Route cable properly to prevent tension on terminals; refit terminal box dust cover
5. Pre-test with multimeter: Measure resistance of both coils under power-off state. Infinite resistance indicates coil open circuit.
6. System Flushing & No-Load Commissioning (Do NOT apply full load pressure directly)

4.1 Initial Flushing

1. Confirm all bolts and pipe connections are completed
2. Jog hydraulic pump, start under low pressure (3～5MPa), circulate and flush system for 5～10 minutes
3. Inspect sealing joints between valve and subplate for external oil leakage. If leakage occurs, depressurize and retighten bolts evenly.

4.2 Electrical Jog Test (Low pressure or zero pressure)

1. Maintain low hydraulic pressure
2. Energize left and right solenoid separately for short pulses (1～2 seconds each time)
3. Normal feedback: Distinct “click” switching sound upon energization

No sound: Low supply voltage, wrong wiring, damaged coil

Abnormal noise / No switching: Contaminated spool; valve disassembly and cleaning required

Safety Rule: Implement interlock in control program to prevent both solenoids energized simultaneously!

4.3 Loaded Gradual Pressure Test

1. After successful low-pressure switching, raise working pressure step by step
2. Perform repeated reciprocating switching and observe actuator motion:

Left solenoid energized → P→A, B→T

Right solenoid energized → P→B, A→T

Power cut → Spring automatically returns spool to initial position

3. Run continuously for 30 minutes for inspection: No leakage on sealing surfaces; normal coil temperature without abnormal overheating.
4. Prohibited Operation Rules (Installation Red Lines)
5. ❌ Do NOT use solenoid housing as leverage point for prying or clamping valve
6. ❌ Do NOT install without removing iron debris on subplate. Scratched sealing surface and spool seizure will occur
7. ❌ Exceed torque limit on M6 bolts, which crushes O-rings and triggers continuous internal leakage
8. ❌ Long-term reverse polarity of DC24V supply, shortens solenoid service life
9. ❌ Simultaneous energization of dual solenoids, results in coil burnout and internal spring damage
10. ❌ Blocked T return line or excessive back pressure leading to switching failure
11. ❌ Operate system directly with heavily contaminated hydraulic oil.
12. On-Site Troubleshooting after Installation
13. Oil leakage between valve and subplate: Depressurize and retighten bolts diagonally; check broken or misplaced O-rings
14. Unable to switch: Measure coil voltage, verify wiring polarity; clean spool if contaminated oil causes seizure
15. Slow switching: Confirm Type90 solenoid is equipped; Type20/72 low-thrust solenoid cannot be substituted; check excessive voltage drop on cable
16. Rapid coil overheating and burnout: Long continuous energization (valve supports ED100% continuous operation, but dual coil simultaneous energization forbidden) or over supply voltage.

7OCEAN DSV-G02-2C-DC24-90 Complete Technical Data

1. Model Code Definition

DSV-G02-2C-DC24-90

1. DSV: Wet armature solenoid directional valve, screw terminal box solenoid

(DSD = DIN quick plug type; identical flow body)

2. G02: Mounting standard NG6 / CETOP03 / ISO4401-AB-03-4-A (6 nominal diameter)
3. 2C: 4/2-way, double solenoid, bi-directional spring return

De-energized initial position: P↔B, A↔T

SOL.a (Left Coil) Energized: P↔A, B↔T

SOL.b (Right Coil) Energized: P↔B, A↔T

⚠️ Never energize both solenoids simultaneously

4. DC24: Nominal control voltage DC24V
5. 90: Type90 high-power wet armature solenoid

Greater actuating force for high-pressure applications; not interchangeable with 20/72/82 solenoids.

2. Hydraulic Performance Data

3. Electrical Data (Type90 DC24V Solenoid)

4. Mechanical & Mounting Data
5. Mounting Standard

Mounting pattern: ISO 4401-AB-03-4-A (CETOP RP121H / DIN24340 Type A)

Matching accessory: G02 standard subplate

2. Fastening Bolts

Specification: M6 hex socket bolts ×4 pcs

Standard Tightening Torque: 5.5～6.5 N·m (Diagonal staged tightening)

3. Weight

Complete valve with dual solenoids: 2.05 kg

4. Recommended Mounting Attitude

Horizontal installation preferred; tilt allowed; long-term inverted installation not recommended.

5. Spool Function Description (2C Spool)

De-energized (Spring Return): P ↔ B, A ↔ T

Left Solenoid SOL.a Energized: P ↔ A, B ↔ T

Right Solenoid SOL.b Energized: P ↔ B, A ↔ T

This is a 2-position valve without neutral position. Spool immediately returns to initial position once any solenoid is de-energized.

6. Selection & Distinction Notes
7. DSV vs DSD-G02

Identical flow body, mounting dimension and spool function; only solenoid wiring interface differs:

DSV = Screw terminal box wiring; DSD = DIN43650 plug connection.

2. Solenoid Suffix: 90 / 82 / 72 / 20

Type90: High thrust version, suitable for high pressure, heavy load and low oil temperature conditions (standard for this model)

Type20/72/82: Standard thrust type. Risk of insufficient shifting force under high pressure; cannot directly replace Type90 solenoid

3. Circuit Warning

Control logic must avoid simultaneous output of two switching signals. Dual coil simultaneous energization leads to rapid temperature rise and solenoid burnout. Electrical interlock circuit is mandatory.

7. Typical Application Industry

Machine tool hydraulic stations, injection molding machines, automated production lines, woodworking machinery, hydraulic fixtures, lifting platforms, auxiliary hydraulic circuits for construction machinery.