Chapter 10.

Hydraulic Valves
One of the most important considerations in any fluid power system is control. If control components are not properly
selected, the entire system does not function as required. In fluid power, controlling elements are called valves. There
are three types of valves:
1. Directional control valves (DCVs): They determine the path through which a fluid transverses a given circuit.
2. Pressure control valves: They protect the system against overpressure, which may occur due to a sudden surge
as valves open or close or due to an increase in fluid demand.
3. Flow control valves: Shock absorbers are hydraulic devices designed to smooth out pressure surges and to
dampen hydraulic shock.

10.1 Directional Control Valves

The function of a DCV is to control the direction of fluid flow in any hydraulic system. A DCV does this by changing
the position of internal movable parts. Any valve contains ports that are external openings through which a fluid can
enter and exit via connecting pipelines. The number of ports on a DCV is identified using the term “way.” Thus, a
valve with four ports is a four-way valve A DCV consists of a valve body or valve housing and a valve mechanism.
The valve mechanism directs the fluid to selected output ports or stops the fluid from passing through the valve. DCVs
can be classified based on fluid path, design characteristics, control methods and construction.

10.1.1 Check valve

The simplest DCV is a check valve. A check valve allows flow in one direction, but blocks the flow in the opposite
direction. It is a two-way valve because it contains two ports. In Fig. 10.1(a), a light spring holds the ball against the
valve seat. Flow coming into the inlet pushes the ball off the seat against the light force of the spring and continues to
the outlet. A very low pressure is required to hold the valve open in this direction. If the flow tries to enter from the
opposite direction, the pressure pushes the ball against the eat and the flow cannot pass through. The graphical symbol
of a check valve along with its no-flow and free-flow directions is shown in Figure 10.1(c).
 Valve seat ball spring

inlet outlet

(a) Operation of ball-type check valve

(b) shape of check valve (c) symbol of check valve

Figure 10.1 Check valve

10.1.2 Pilot operated check valve

A pilot-operated valve along with its symbol is shown in Fig. 10.2. This type of check valve always permits free flow
in one direction but permits flow in the normally blocked opposite direction only if the pilot pressure is applied at the
pilot pressure point of the valve. The check valve poppet has the pilot piston attached to the threaded poppet stem by
a nut. The light spring holds the poppet seated in a no-flow condition by pushing against the pilot piston. The purpose
of the separate drain port is to prevent oil from creating a pressure build-up at the bottom of the piston. The dashed
line in the graphical symbol represents the pilot pressure line connected to the pilot pressure port of the valve. Pilot
check valves are used for locking hydraulic cylinders in position.
 (a) Operation of pliot-operated check valve

(b) shape of pilot-operatedcheck valve (c) symbol of check valve

Figure 10.2 Pilot-operated check valve

10.1.3 Shuttle valve

A shuttle valve allows two alternate flow sources to be connected in a one-branch circuit. The valve has two inlets P1
and P2 and one outlet A. Outlet A receives flow from an inlet that is at a higher pressure. Fig. 10.3 shows the operation
of a shuttle valve. If the pressure at P1 is greater than that at P2, the ball slides to the right and allows P1 to send flow
to outlet A. If the pressure at P2 is greater than that at P1, the ball slides to the left and P2 supplies flow to outlet A. A
shuttle valve is called an “OR” valve because receiving a pressure input signal from either P1 or P2 causes a pressure
output signal to be sent to A. Graphical symbol of shuttle valve is also shown in Fig. 10.3.
 (a) Operation of pliot-operated check valve

(b) shape of shuttle valve (c) symbol of shuttle valve

Figure 10.3 Shuttle valve

10.1.4 2-way 2-position DCV

Directional control valves(DCV) are classified by positions, ways, and ports, and are displayed by rectangles and
arrows symbolically in following Fig.10.4.
 (a) 2 position 1 way 2 port (b) 2 position 2 way 3 port

(c) 2 position 4 way 4 port (d) 3 position 4 way 4 port

Figure 10.4 Classification of directional control valves

Two-way valves either block or allow flow from an inlet to an outlet. They also allow the outlet to flow back to the
tank when the pump is blocked. A Two -way valve has three ports, namely, a pressure inlet (P), an outlet to the system
(A) and a return to the tank (T). Fig. 10.5 shows the operation of a 2-way 2-position valve. In the normal position
(spool position 2 of Fig. 10.5), the pressure port P is blocked and outlet A is connected to the tank. In the actuated
position (spool position 1 of Fig. 10.5), the pressure port is connected to outlet A and the tank port is blocked.
Application of 2-way 2-position DCV for controlling a single-acting cylinder: A 2-way 2-position DCV is used to
control a single-acting cylinder. Right side position in Fig. 10.5(c)shows the valve in its normal position in which the
pressure port is blocked and the outlet is returned to the tank. This allows the force off to act on the piston and retract
the cylinder. The cylinder remains in the retracted position as long as the valve is in this position. The left side position
in Fig. 10.5(c) connects the pressure port P with outlet A and the tank port is blocked. This applies pump flow and
pressure to the piston and the cylinder extends against the light force of the spring.

(a) Operation of 2-way 2-position DCV (b) Shape of 2-way 2-position DCV
 (c)Controlling a single-acting cylinder by 2-way 2-position DCV

Figure 10.5 Operation and application circuit of 2-way 2-position directional control valve

10.1.5 4-way 2-position DCV

Four-way DCVs are capable of controlling double-acting cylinders and bidirectional motors. Fig 10.6 shows the
operation and complete graphic symbol of a typical 4-way 2-position DCV. A four-way has four ports labeled P, T, A
and B. P is the pressure inlet and T is the return to the tank; A and B are outlets to the system. In the normal position,
pump flow is sent to outlet A. Outlet B is connected to the tank. In the actuated position, the pump flow is sent to port
B and port A connected to tank T. In four-way DCVs, two flows of the fluids are controlled at the same time, while
two-way and three-way DCVs control only one flow at a time.

(a) Operation of 4-way 2-position DCV (b) Shape of 4-way 2-position DCV
 (c)Controlling a single-acting cylinder/hydraulic motor by 2-way 2-position DCV

Figure 10.6 Operation and application circuit of 4-way 2-position DCV

10.1.6 4-way 3-position DCV

In Fig. 10.7, we see the symbolic representation of the four-way valve. Notice that the ports are labeled on the center
envelope, which represents the flow path configuration in the spring-centered position of the spool. Also observe the
spring and lever actuation symbols used at the ends of the right and left envelope. These imply a spring-centered,
manually actuated valve. It should be noted that a three-position valve is used when it is necessary to stop or hold a
hydraulic actuator at some intermediate position within its entire stroke range.

(a) Operation of 4-way 3-position DCV with closed center (b) Shape of 4-way 3-position DCV
 (b) Symbol of 4-way 3-position DCV with closed center

(d) Circuit diagram of a single-acting cylinder by 4-way 3-position DCV with closed center
 (e) Application of control cylinder motion by 4-way 3-position DCV with closed center

Figure 10.7 Operation and application of control single acting cylinder by 4-way 3-position DCV

Most three-position valves have a variety of possible flow path configurations. Each four-way valve has identical flow
path configurations in the actuated positions but different spring-centered flow paths. This is illustrated in Fig. 10.8.
Notice that the open-center type connects all ports together. In this design the pump flow can return directly back to
the tank at essentially atmospheric pressure. At the same time, the actuator (cylinder or motor) can be moved freely
by applying an external force. The closed-center design has all ports blocked. In this way the pump flow can be used
for other parts of the circuit. At the same time, the actuator connected to ports A and B is hydraulically locked. This
means it cannot be moved by the application of an external force. The tandem center design also results in a locked
actuator. However, it also unloads the pump at essentially atmospheric pressure. For example, the closed-center design
forces the pump to produce flow at the high-pressure setting of the pressure relief valve. This not only wastes pump
design horsepower but promotes wear and shortens pump life, especially if operation in the center position occurs for
long periods of time. Another factor is that the wasted horsepower shows up as heat, which raises the temperature of
the oil. This promotes oil oxidation, which increases the acidity of the oil.
 Figure 10.8 Various center flow paths for 4-way 3-position DCV

10.1.7 Actuating devices

Direction control valves may be actuated by a variety of methods. Actuation is the method of moving the valve element
from one position to another. There are four basic methods of actuation: Manual, mechanical, solenoid-operated and
pilot-operated. Several combinations of actuation are possible using these four basic methods. Graphical symbols of
such combinations are given in Table 10.1.
1. Manually operated: In manually operated DCVs, the spool is shifted manually by moving a handle pushing a
button or stepping on a foot pedal. When the handle is not operated, the spool returns to its original position by
means of a spring.
2. Mechanically operated: The spool is shifted by mechanical linkages such as cam and rollers.
3. Solenoid operated: When an electric coil or a solenoid is energized, it creates a magnetic force that pulls the
 armature into the coil. This causes the armature to push the spool of the valve.
4. Pilot operated: A DCV can also be shifted by applying a pilot signal (either hydraulic or pneumatic) against a
piston at either end of the valve spool. When pilot pressure is introduced, it pushes the piston to shift the spool.

Table 10.1 Valve actuating method and graphical symbols

10.2 Pressure control valves

Pressure-control valves are often difficult to identify mainly because of the many descriptive names given to them.
The function of the valve in the circuit usually becomes the basis for its name. The valves used for accomplishing the
above-mentioned system functions are therefore given the following names:
1. Pressure-relief valve
2. Pressure-reducing valve
3. Unloading valve
4. Counterbalance valve
5. Pressure-sequence valve
10.2.1 Pressure-relief valve
The most widely used type of pressure control valve is the pressure-relief valve because it is found in practically every
hydraulic system. Schematic diagram and graphic symbol of simple relief valve is shown in Fig. 10.9. It is normally
a closed valve whose function is to limit the pressure to a specified maximum value by diverting pump flow back to
the tank. A poppet is held seated inside the valve by a heavy spring. When the system pressure reaches a high enough
value, the poppet is forced off its seat. This permits flow through the outlet to the tank as long as this high pressure
level is maintained. Note the external adjusting screw, which varies spring force and, thus, the pressure at which the
valve begins to open (cracking pressure). It should be noted that the poppet must open sufficiently to allow full pump
flow. The pressure that exists at full pump flow can be substantially greater than cracking pressure. The pressure at
full pump flow is the pressure level that is specified when referring to the pressure setting of the valve. It is the
maximum pressure level permitted by the relief valve.

(a) Operation of direct acting pressure relief valve

(b) Symbol of direct acting pressure relief valve

 (c) Shape of direct acting pressure relief valve

(d) Circuit diagram of control maximum pressure by relief valve

Figure 10.9 Operation and application circuit of direct acting pressure relief valve

Example 10.1
A pressure-relief valve has a pressure setting of 140 bar. Compute the kW loss across this valve if it returns all the
flow back to the tank from a 0.0016 m3/s pump
Solution: kW power = 𝑝𝑄 = (140 × 105 N/m2 )(0.0016m3 /s) = 22400w = 22.4kW

10.2.2 Pressure-reducing valve

A pressure-reducing valve (which is normally open) is used to maintain reduced pressures in specified locations of
hydraulic systems. It is actuated by downstream pressure and tends to close as this pressure reaches the valve setting.
Schematic diagram and graphic symbol of pressure reducing valve is shown in Fig. 10.10. A pressure-reducing valve
uses a spring-loaded spool to control the downstream pressure. If the downstream pressure is below the valve setting,
the fluid flows freely from the inlet to the outlet. Note that there is an internal passageway from the outlet which
transmits outlet pressure to the spool end opposite the spring. When the outlet (downstream) pressure increases to the
valve setting, the spool moves to the right to partially block the outlet port. Just enough flow is passed to the outlet to
maintain its preset pressure level.
(a) Operation of pressure reducing valve

(b) Symbol of pressure reducing valve

 (c) Shape of direct acting pressure reducing valve

(d) Circuit diagram of reducing pressure by pressure reducing valve

Figure 10.10 Operation and application circuit of Pressure-reducing valve