Directional Control Valves

Directional control valves perform only three functions:

stop fluid flow

allow fluid flow, and

change direction of fluid flow.

These three functions usually operate in combination.

The simplest directional control valve is the 2-way valve. A 2-way valve stops flow or
allows flow. A water faucet is a good example of a 2-way valve. A water faucet allows
flow or stops flow by manual control.
A single-acting cylinder needs supply to and exhaust from its port to operate. This
requires a 3-way valve. A 3-way valve allows fluid flow to an actuator in one position
and exhausts the fluid from it in the other position. Some 3-way valves have a third
position that blocks flow at all ports.
A double-acting actuator requires a 4-way valve. A 4-way valve pressurizes and
exhausts two ports interdependently. A 3-position, 4-way valve stops an actuator or
allows it to float. The 4-way function is a common type of directional control valve
for both air and hydraulic circuits. A 3-position, 4-way valve is more common in
hydraulic circuits.
The 5-way valve is found most frequently in air circuits. A 5-way valve performs the
same function as a 4-way valve. The only difference is an extra tank or exhaust port.
(Some suppliers call their 5-way valves, 5-ported 4-ways.") All spool valves are five
ported, but hydraulic valves have internally connected exhaust ports going to a
common outlet. Because oil must return to tank, it is convenient to connect the dual
tank ports to a single return port. For air valves, atmosphere is the tank, so exhaust
piping is usually unimportant. Using two exhaust ports makes the valve smaller and
less expensive. As will be explained later, dual exhausts used for speed-control
mufflers or as dual-pressure inlets make this configuration versatile.
Following are schematic symbols for commonly used directional control valves.
2-way directional control valves
A 2-way directional valve has two ports normally called inlet and outlet. When the

inlet is blocked in the at-rest condition, as shown in Figure 8-1, it is referred to as

"normally closed" (NC). The at-rest box or the normal condition is the one with the
flow lines going to and from it.
The boxes or enclosures represent the valves positions. In Figure 8-1, the active box
shows blocked ports, or a closed condition, while the upper box shows a flow path.
When an operator shifts the valve, it is the same as sliding the upper box down to
take the place of the lower box. In the shifted condition there is flow
from inlet to outlet. Releasing the palm button in Figure 8-1 allows the valve spring
to return to the normal stop flow condition. A 2-way valve makes a blow-off device or
runs a fluid motor in one direction. By itself, a 2-way valve cannot cycle even a single
acting cylinder.

Figure 8-2 shows a "normally open" (NO) 2-way directional valve. Energizing the
solenoid on this valve stops fluid flow.
Valve operators come in different types. Figure 8-3 shows a solenoid pilot operator
using solenoid-controlled pressure from the inlet port to move the working
directional spool. Figure 8-4 shows a cam-operated valve. A moving machine
member usually operates this type valve.
3-way directional control valves
A 3-way valve has three working ports. These ports are: inlet, outlet,
and exhaust (ortank). A 3-way valve not only supplies fluid to an actuator, but allows
fluid to return from it as well. Figures 8-5 through 8-10 show schematic symbols for
3-way directional control valves.

Figure 8-9. Solenoid pilot-operated 3-way selector valve.

Figure 8-6 depicts an all-ports-blocked, 3-way, 3-position valve. A valve of this type
connected to a single-acting, weight- or spring-returned cylinder could extend, retract, or
stop at any place in the stroke.
Some 3-way valves select fluid flow paths as in Figure 8-9. Use a spool-type valve for
this operation. Another flow condition is the diverter valve shown in Figure 8-10. A
diverter valve sends fluid to either of two paths.

Figure 8-10. Palm-button-operated 3-way diverter valve.

4-way directional control valves

Figures 8-11 to 8-15 show different configurations available in 4-way directional control
valves. They range from the simple, two-position, single, direct solenoid, spring-return
valve shown in Figure 8-11, to the more complex three-position, double solenoid, pilotoperated, spring-centered, external-pilot supply, external drain valve shown in Figure 815.

Figure 8-11. 4-way, 2-position direct solenoid-operated spring return.

Lines to the boxes show flow to and from the valve, while lines with arrows in the boxes
show direction of flow. The number of boxes tells how many positions the valve has.
Figure 8-12 shows a single solenoid, spring-centered valve. This valve has a third
position but there is no operator for it. Use this spring-centered, single solenoid valve
in control circuits for special functions. In the past, to get this configuration, you only
had to wire one solenoid of a double-solenoid, three-position valve.

Figure 8-12. 4-way, 2-position direct solenoid-operated spring centered.

Figure 8-13 shows another unusual 4-way configuration. This valve shifts from an
actuator moving flow path to center condition for certain special circuits.
5-way directional control valves
Figures 8-16 through 8-20 show symbols of some 5-way air valves. Most spool-type
air valves come in a 5-way configuration. Because air usually exhausts to
atmosphere, the extra exhaust port is no problem.
Many valves use the two exhaust ports for speed control mufflers. Mufflers not only
make the exhaust quieter, but throttle the exhaust, which in turn controls cylinder
speed in a meter-out circuit.

Figure 8-13. 4-way, 2-position direct solenoid-operated spring return.

Another example later in this section shows dual exhaust ports piped with different
pressures to save air. Also use dual inlet piping to make an air cylinder operate
quickly and smoothly. (See Figures 8-48 through 8-55.)

Figure 8-14. 4-way, 2-position solenoid, pilot operated detented, line-mounted.

Most air cylinders stroke from one extreme to the other. A two position, single solenoid,
spring return valve is sufficient for this operation. About 90% of air circuits use this type
of valve. To stop an air cylinder in mid-stroke, use the 3-position valve shown in Figures
8-19 through 8-21.

Figure 8-17.Line-mounted, solenoid pilot-operated, 2-position,spring returned 5-way valve.

It is difficult if not impossible to accurately stop an air cylinder any place other
than at end of the stroke. When the cylinder moves slowly, a repeatable mid stroke
position of plus or minus an inch might be possible. The problem is, if the load on
the cylinder changes or there is any slight leak in the piping or seals, it will not hold
position once it stops.

Figure 8-18. Line-mounted, hand lever-operated, 2-position, spring-returned 5-way valve.

Three-position valves come in several styles, including: cylinder ports open as seen
in Figure 8-19; all ports blocked as seen in Figure 8-20; and pressure to cylinder
ports as seen in Figure 8-21.
Using 2-way valves
Figures 8-22, 8-23, and 8-24 show some uses for 2-way directional control valves.

Figure 8-19. 5-way, 3 position, spring-centered solenoid, pilot-operated, cylinder ports open-center
condition, line mounted.

One use is the blow-off function shown in Figure 8-22. A 2-way valve in Figure 823 operates a one-direction motor with an open exhaust in the motor housing. The circuit

in Figure 8-24 works well for electrically unloading a pump for easy start up and/or
reduced heat generation
Figure 8-25 shows a weight-returned, single-acting cylinder powered by a 2-way in
the<b>at rest</b> condition. At first sight it looks as if this circuit might work.
Shifting the 2-way valve, or extending, sends fluid to the cylinder cap end and it
extends.

Figure 8-20. 5-way, 3 position, spring-centered solenoid, pilot-operated, all ports blocked center condition,
line mounted.

The problem comes when the 2-way returns to normal at theend of cycle. Instead of the
cylinder retracting after the solenoid de-energizes, it stays in the extended position. The
cylinder would only return if the valve, cylinder seals, or pipe connections leak.

Figure 8-21. 5-way, 3 position, spring-centered pressure to cylinder ports, exhausts blocked center
condition, solenoid-pilot operated, line mounted.

Figure 8-26 shows a circuit that operates a single-acting cylinder with 2-way valves. One
(NO) and one (NC) 2-way directional valve piped to the cap end cylinder port allows
fluid to enter and exhaust from it. Actuating both operators simultaneously extends the
cylinder. According to valve size and inlet air flow, the cylinder might not extend if just
energizing the (NC) valve. If the cylinder extends with only one valve actuated, it would
be slow and waste a lot of air.

Figure 8-22. Blow-off.

Figure 8-23. Running a one-direction fluid motor.

Figure 8-24. Unloading a pump.

Figure 8-25. Using one 2-way valve to operate a single-acting cylinder.

Figure 8-27 shows four 2-way valves piped to operate a double-acting cylinder. A
pair of 2-way valves at each cylinder port gives a power stroke in both directions.

Energize and de-energize all four valves simultaneously to cycle the cylinder and
keep from wasting fluid.

Figure 8-26. Operating a single-acting cylinder with two 2-way valves.

Four 2-way valves may seem to be a complex and expensive way to operate a
cylinder. However, in the past few years, poppet type slip-in cartridge valves have
been operating large bore hydraulic cylinders this way. See chapter four on Cartridge
Valves for the advantages of these valves in high flow circuits.
Using 3-way valves
Figure 8-28 shows a 3-way valve, used to select Pr. 1 orPr. 2. Use a spool type
directional control valve in this type of circuit. Spool valves normally take pressure at
any port without malfunction. Poppet design valves normally take pressure at the
inlet port only.

Figure 8-27. Operating a single-acting cylinder with four 2-way valves.

Since the example selector valve is solenoid pilot-operated, it is important to

determine which port has the higher pressure. Most solenoid pilot-operated valves
take air from the normal inlet port to operate the pilot section. If both inlet pressures

are too low to operate the valve, plumb an external pilot supply from the main air
system.
When it is necessary to lock out one of two circuits while the other one operates, the
hookup in Figure 8-29 works well.
While circuit one has fluid going to it, working on circuit two is no problem. Use a
spool type valve here also. Poppet valves usually only take pressure at one port.

Figure 8-28. Pressure selector.

The most common limit valve is a miniature 3-way like the one shown in Figure 830. This particular example is (NC). Contact with a machine member opens it.
Except for bleeder type control circuits, a limit valve requires at least a 3-way
function.
Once this normally closed valve shifts, it passes a signal on to continue the cycle. In
normal condition, fluid in the control circuit exhausts through the exhaust port.

Figure 8-29. Fluid diverter.

Figure 8-31 shows a single-acting cylinder with a 3-way valve powering it. Energizing
the solenoid, or extending, allows flow to move to the cylinder port and it extends.
Deenergizing the solenoid or retracting, lets the valve shift to home position, and the
cylinder retracts from outside forces.
The exhaust port on a 3-way valve lets fluid in the cylinder escape to atmosphere.

Figure 8-30. NC limit valve.

Figure 8-31. Operating a single-acting cylinder with one 3-way valve.

To operate a double-acting cylinder with 3-way valves, use the hookup shown in
Figure 8-32. With a 3-way directional valve at both ports, both extend and retract
strokes of a double-acting cylinder have force.
Some manufacturers use dual 3-way valves to conserve air. Piping between the valve
and cylinder ports wastes air. Every time a cylinder cycles, the lines to both ports fill
and exhaust. The longer the valve-to-cylinder lines are, the greater the air waste.
Mounting air valves directly to the cylinder ports minimizes air waste. The higher
cycle rate results in greater savings.

Figure 8-32. Operating a double-acting cylinder with two 3-way valves.

Lowering pressure at the rod end port is another way to save air with dual 3-way
valves mounted directly to the cylinder port. As discussed before, reducing air
pressure at the cylinder uses less compressor horsepower. Usually, force required to
return a cylinder is minimal, so lower pressure at the rod port saves energy.
Speed-control mufflers in the direct-mounted 3-way valves independently control
the extend and retract speed of the cylinder. This saves piping time and the cost of
flow control valves.
Figure 8-33 shows an air cylinder inching circuit. It is possible to inch an air circuit
if accuracy and repeatability are not important. An inching circuits repeatability is
usually not closer than 1 in. if travel speed is slow. Faster travel speeds give less
control.

Figure 8-33. Inching circuit for a double-acting cylinder with two 3-way spring-centered valves.

A 3-way valve can replace a 2-way valve. To duplicate the 2-way function, block the
exhaust port of the 3-way valve. Blocking the exhaust of a 3-way is usually not

necessary for most 2-way applications. Using 3-way valves in place of 2-way valves
reduces inventory cost and saves time.
Using 4-way valves
See Figures 8-34 to 8-36 for some uncommon uses of 4-way directional control
valves. Using directional controls in ways other than normal is a common practice.
Make sure the valve is capable of pressure in all ports before applying it to some of
these circuits. If the valve is solenoid pilot-operated, where does pilot supply come
from? Also check with the manufacturer if there is any doubt about the valves
performance in an unusual application.
To make a high flow 2-way valve from a 4-way valve try the circuit shown in Figure
8-34. Connect pump flow to the normal inlet port and its outlet port, then connect
the other outlet port to the normal tank port and on to the system. In the at-rest
condition there is no flow through the valve.

Figure 8-34. Double flow capacity.

When the valve shifts, flow is fromP through B to system and from A through T to
system. A valve rated at 10 gpm is now good for 20 gpm with little or no increase in
pressure drop. Make sure the valve is capable of backpressure at the tank port.
This piping arrangement comes in handy in hydraulic circuits, since most
manufacturers do not offer a 2-way valve. Also, a lot of 2-way hydraulic valves only
stop flow in one direction, so they are useless in a bi-directional flow line.
For a full time regeneration circuit, pipe the 4-way as shown in Figure 8-35. Read
Chapter 17 for a full explanation of this regeneration circuit.

Figure 8-35. Full time regeneration.

Figure 8-36 shows how to pressurize both ends of the cylinder when a 4-way valve
centers. When a cylinder retracts to pick up another part, it often has to go too far to make
sure it is behind the part. Low backpressure from the check valve makes the cylinder
creep forward at low power so the cylinder is in contact with a part before the next cycle
starts.
Figure 8-37 shows the normal hookup of a 4-way directional valve. A double-acting
cylinder only needs one 4-way directional valve to extend and retract it. The three
sequences show a 4-way valve in action.

Figure 8-36. Low-pressure cylinder extend.

Add flow controls or a counterbalance valve to complete the circuit when there is weight
on the rod. Note the port hookup is A to cap and B to rod.
Using this port connection arrangement consistently makes it is easy to wire the
circuit because the electrician knows Asolenoid extends the cylinder while B solenoid
retracts it. Maintenance persons always know which manual override to push during
trouble shooting or setup.

Figure 8-37. Operating a double-acting cylinder with one 4-way valve.

Most hydraulic directional control valves are 3-position. Valve center conditions
perform different functions in relation to the actuator and pump.

Figure 8-38. Inching circuit with pump unloaded, cylinder floating.

An all-ports open center condition directional valve unloads the pump and allows the
actuator to float as shown in Figure 8-38. This reduces heat build up and allows
opposing forces to move the cylinder without building backpressure.
To block the cylinder while unloading the pump, use the center condition shown in
Figure 8-39. Most hydraulic valves are a metal-to-metal fit spool design, so do not
depend on the cylinder setting dead still with a tandem center spool. If there are
outside forces on the cylinder, it will creep when the valve centers.
If the cylinder needs to float while blocking pump flow, use the center condition
shown in Figure 8-40.

Figure 8-39. Inching circuit with pump unloaded, cylinder blocked.

Figures 8-41 to 8-46 show several commonly used 4-way hydraulic valve center
conditions. The first four account for about 90% of all 3-position hydraulic valves in
use.
The center condition of a 3-position valve can unload a pump, open actuator ports to
tank for free movement, block actuator ports to stop movement, give regeneration, or
work in combinations of these functions.
Figure 8-41 shows an all-ports-open center condition valve. The open center
condition unloads the pump and allows the actuator to coast to a stop or float. In the
crossover or transition condition it causes very little shock. Fixed volume pumps use
this center condition.

Figure 8-40. Inching circuit with pump blocked, cylinder floating.

The all-ports-blocked center condition valve of Figure 8-42 appears to block the cylinder
ports. In actual use, leakage oil across the spool lands pressurizes A and B ports, possibly
causing a single rod cylinder to extend. This is not a good choice for stopping and
holding a cylinder as the symbol seems to indicate. To positively stop a cylinder, use a
valve with the cylinder ports hooked to tank, and pilot-operated check valves in the
cylinder line or lines. (See the section on Check Valves as Directional Valves.)

Figure 8-41. All ports open, center condition.

The float center valve of Figure 8-43 allows the actuator to float while blocking pump
flow. Pump output is available for other valves and actuators with this center
condition. It also works well for pilot-operated check valve locking circuits or with
counterbalance valves.

Figure 8-42. Ports blocked, center condition.

This is the normal center condition for the solenoid valve on a solenoid pilot-operated,
spring-centered directional valve.

Figure 8-43. Float center condition.

Figure 8-44 shows a tandem center valve. A tandem center valve lets the pump
unload while blocking the cylinder ports. The cylinder sits still unless there is an
outside force trying to move it. Any metal-to-metal fit spool valve never fully blocks
flow. With external forces working on the cylinder, it may slowly creep with the valve
centered. This is another common center condition for fixed volume pumps.

Figure 8-44. Tandem center condition.

The regeneration center position of the valve in Figure 8-45 pressurizes and
connects both ports of a cylinder to each other. Connecting pressure oil to both
cylinder ports and to each other regenerates it forward when the valve centers. This
valve is the pilot operator for hydraulically centered directional valves or normally
closed slip in cartridge valves.

Figure 8-45. Regeneration center condition.

To unload the pump while blocking the cylinder from moving, use the valve shown in
Figure 8-46. However, the metal-to-metal fit spool will not lock the cylinder when
there are external forces.
Figures 8-47 to 8-48 show what is commonly referred to as the crossover or
transition condition of a spool. In some actuator applications it is important to
know what the valve port flow conditions are as it shifts. As shown in these figures,
dashed lined boxes show crossover condition. Normally discussions about crossover
conditions cover open or closed types; in reality, the crossover condition may be
a combination of these and may be different on either side of center.

Figure 8-46. Pump unload, port B blocked, center condition.

Open crossover stops shock while the spool shifts, while a closed crossover reduces
actuator override travel. If the crossover condition is important to the circuit or machine
function, show it on the schematic drawing.
Figure 8-49 shows an all ports blocked center condition, solenoid pilot-operated
valve, as a simplified and complete symbol. On most schematics, the simplified
symbol is sufficient. The solenoid slash and energy triangle in the operator box show
the valve has a solenoid operated valve piloting a pilot-operated valve.

Figure 8-47. Open crossover or transition condition.

The boxes show the function of the main or working spool that controls the actuator.
On valves with other hardware added (here, pilot chokes and stroke limiters), it is
better to show the complete symbol. Both symbols in Figure 8-49 represent the same
valve. The complete symbol gives more information about the valve function and
helps with troubleshooting and valve replacement.

Figure 8-48. Closed crossover or transition condition.

Figure 8-49. Solenoid pilot-operated valve with pilot chokes and stroke limiters. Internal pilot supply (X)
and external drain (Y).

Using 5-way air valves

The 5-way selector valve and shuttle valve in Figure 8-50 works where a 3-way selector
may not. The 3-way selector does fine when going from low to high pressure, but if there
is no air usage to allow expansion, it is almost impossible to go from high to low
pressure.
The 5-way and shuttle valve arrangement gives an exhaust path for high-pressure air
when shifting to low pressure. After the air exhausts to the lower pressure, PR.1, the
shuttle shifts and low pressure holds in the system.

Figure 8-50. Pressure selector.

Figure 8-51 shows a pair of 5-way valves piped to act like a three way light switch. Either
valve moves the cylinder to its opposite position when activated.
Figure 8-52 shows the normal hookup of a 5-way valve. Normally, input air goes to
the center port of the side with three ports. A lot of air valve manufacturers call this
#1 port. In the at rest condition, air flows from #1 to #4 port and on to the cylinder
rod end, while #2 port exhausts the cylinder cap end through #3 port.
After shifting the valve, or extending, air flows from #1 port through #2 port to the
cylinder cap end. Flow from the cylinder rod end goes to #4 port and exhausts

through #5 port. The exhaust ports often have speed control mufflers to reduce noise
and control the amount of exhaust flow. Speed control mufflers give individual
meter-out speed control in each direction of travel.

Figure 8-51. Operating an actuator from two locations.

Deenergizing the solenoid, or retracting, lets the valve spring return to its normal
condition causing the cylinder to retract.
In Figure 8-53, the 5-way has a dual inlet instead of dual exhaust. Use a spool type
valve for this hookup, since it takes pressure at any port without malfunction.
On most air circuits the cylinder does little or no work on the retract stroke. Putting
low pressure on the rod side of the cylinder uses less compressor air without
affecting the operation. This air savings results in lower operating cost and leaves
more air to run other actuators. Install flow controls in the lines to the cylinder ports
for individual speed control.

Figure 8-52. Operating a double-acting cylinder with one 5-way valve.

If the valve is solenoid pilot-operated, the supply to the pilot valve usually comes from
port #1. This means, with a dual pressure inlet, pilot supply must come from some other
source. On the circuit in Figure 8-53 a pilot line from system pressure goes directly to the
pilot valve. System pressure goes into the external pilot supply port and a plug shuts off
the internal pilot port. Changing the pilot line in the field with assistance from the
suppliers catalog is quite easy.

Figure 8-53. Air-saving circuit using a 5-way valve.

Figures 8-54 to 8-61 show another reason for using dual pressure inlets. They depict air
cylinder movement with conventional hookup. The cylinder pauses before raising and
drops rapidly when starting to retract.
Dual-pressure 5-way valves for air cylinder actuation
A vertical, up-acting air cylinder, with a heavy load, gives sluggish and jerky
operation when valved conventionally. Figure 8-54 shows a conventional 5-way valve
hook up on a cylinder raising a 600-lb load. This figure shows weight, cap and head
end areas, and pressures at both cylinder ports.

Figure 8-54. Cylinder at rest.

When the directional valve shifts, as seen in Figure 8-55, there is a pause before the
cylinder extends. The weight-to-cylinder force ratio and the rate of cylinder travel
speed control the length of pause. The heavier the weight and the slower the cylinder
speed, the longer the pause. The delay could be three to four seconds in extreme
cases.

The pause comes from weight pushing down along with force from air pressure on
the cylinder rod end. At the moment the valve shifts to extend the cylinder, down
forces are up to 1240-lb while up force is only 800 lb. As long as down forces exceed
up force, the cylinder will not move. The slower the air exhausts, the longer it takes
to get enough differential pressure across the cylinder piston to move it. The speed of
exhausting air controls how fast the cylinder moves once it starts.

Figure 8-55. Valve just shifted, cylinder pauses.

Figure 8-56. Cylinder starts to move after rod-end pressure drops.

When pressure in the head end of the cylinder reaches about 15 psi, as shown in
Figure 8-56, the cylinder starts to move. It moves up smoothly and steadily as long as
the load remains constant.
When the valve shifts to retract the fully extended cylinder, there is another problem.
Figure 8-57 shows the cylinder at rest at the top. Up force is 800 lb from air pressure
on the cap end, and down force is 600 lb from the weight.

Figure 8-57. Cylinder travels to end of stroke.

Figure 8-58. Valve shifted to retract cylinder, which drops rapidly.

When the directional valve returns to normal, as shown in Figure 8-58, down force
quickly changes to 1240 lb. Now the load drops rapidly until air pressure in the cap
compresses to approximately 120 psi. It takes about 120 psi on the 10-in.2 area to
slow the cylinders rapid retraction.
Both pauses that occur when extending and retracting are eliminated by using the
dual-inlet feature of a 5-way valve.
With a dual inlet pressure circuit shown in Figure 8-59, the cap end port has 80 psi
while the rod end port is only 15 psi. This sets a pressure differential across the
piston before the valve shifts.

Figure 8-59. Dual-pressure valve at rest.

Figure 8-60. Valve shifts, cylinder starts moving quickly.

When the valve shifts, as seen in Figure 8-60, down force is 720 lb and up force is
800 lb. The cylinder starts to move almost immediately and continues moving
smoothly to the end.
In Figure 8-61 the valve shifts and the cylinder retracts. With the head end regulator
set at 15 psi, down force from air pressure and the load is almost offset by up force.
The load lowers smoothly and safely without lunging or bouncing, as fast as cap end
air exhausts. In figure 8-59 to 8-61, the cylinder strokes smoothly and quickly in both
directions with dual-pressure valve.

Figure 8-61. Valve shifts to normal, cylinder moves with no lunge.

Check valves as directional valves

Normally a check valve is not thought of as a directional control valve, but it does
stop flow in one direction and allow flow in the opposite direction. These are two of
the three actions a directional control valve can perform. An inline check valve stops
any chance of reverse flow and is useful and/or necessary in many applications.
Figure 8-62 shows the symbol for a plain check valve.
Another application for a check valve is a relief function, which can be seen in Figure
8-63. Heat exchangers, filters, and low-pressure transfer pumps often need a lowpressure bypass or relief valve. A check valve with a 25-125 psi spring makes an
inexpensive, non-adjustable, flow path for excess fluid. It protects low-pressure
devices in case of through flow blockage. Pilot operated directional valves commonly
use a check valve in the tank or pump line to maintain at least 50-75 psi pilot
pressure during pump unload. Some manufacturers make a check valve with an
adjustable spring, for pressures up to 200 psi or more.

Figure 8-62. Plain check valve.

Some check valves have a removable threaded plug in them that may be drilled to allow
controlled flow in the reverse direction. The symbol in Figure 8-64 shows how to
represent this in a symbol. A common use for a drilled check valve is as a fixed, tamper
proof, flow control valve. Fluid free flows in one direction, but has controlled flow in the
opposite direction. The only way to change flow is to change the orifice size. This flow
control valve is not pressure compensated.

Figure 8-63. Backpressure check valve

Many of the circuits in this manual show standard check valves in use. Hi-L pump
circuits, reverse free flow bypass for flow controls, sequence valves or counterbalance
valves, and multi-pump isolation, to name a few. Figure 8-65 shows some other
applications for check valves.
When the tank is higher than the pump or directional valves, always install some
means to block flow lines for maintenance. If the valves are not blocked, the tank
must be drained when changing a hydraulic component. Shut-off valves are the only
option for lines that flow out of the tank to a pump or other fluid using device.

Figure 8-64. Check valve with orifice plug.

To avoid running the pump dry, its shutoff should have a limit switch indicating full open
before the electrical control circuit will allow the pump to start. All return lines though,
can have a check valve piped as shown in Figure 8-65. A check valve with a low-pressure
spring, called an tank isolation check valve, on each return line allows free flow to tank,
while blocking flow out of it. A check valve in the tank lines makes shut off automatic
and eliminates chances of blowing a filter or wrecking a valve at startup.

Figure 8-65. Check valves in different circuit applications.

The backpressure check valve in the pump line maintains a minimum pilot pressure while
the pump unloads. Here it is in the line feeding the directional valves, other times it is in
the tank line. In either case it provides pilot pressure to shift the directional valves when a
new cycle starts.
The circuit in Figure 8-65 also shows an anti-cavitation check valve for the cylinder
with a relief valve to protect it from over pressure. An external force can pull against
the trapped oil in the cylinder and cause damage or failure without relief protection.
When outside forces move the cylinder, fluid from the rod end goes to the cap end,
but is not enough to fill it. If a void in the cap of the cylinder is no problem then an
anti-cavitation check valve is unnecessary. However, this void can cause erratic
action when the cylinder cycles again, so install an anti-cavitation check valve. The
anti-cavitation check valve has a very low-pressure spring, which requires 1-3 psi to
open, so it allows tank oil to fill any vacuum void that might form. The anticavitation check valve has no effect during any other part of the cycle.
Pilot-operated check valves
There are some circuits that need the positive shut off of a check valve but in which
reverse flow is also necessary. The following images show symbols of pilot-operated
check valves that allow reverse flow. Figure 8-66 shows the symbol for a standard
pilot to open check valve. Figure 8-67 shows a pilot-operated check with a
decompression feature. The symbol in Figure 8-68 shows a pilot-operated check
valve with an external drain for the pilot piston. Each of these pilot-operated check
valves allow reverse flow, but two of them have added features to overcome certain
circuit conditions.

Figure 8-66. Pilot-operated check valve.

Figure 8-67. Pilot-operated check valve with decompression poppet.

Figure 8-68. Pilot-operated check valve with external drain.

To hold a cylinder stationary, it must have resilient continuous non-leaking seals, no

plumbing leaks, and a non-leaking valve. Metal-to-metal fit spool valves will not hold
a cylinder for any length of time. As shown in Figure 8-69, a blocked center valve can
actually cause a cylinder to creep forward. Vertically mounted cylinders with down
acting loads always creep when using a metal-to-metal fit spool valve. Hydraulic
motors always have internal leakage so the circuits shown here will not hold them

stationary. Figures 8-70, 8-71, and 8-72 show a typical pilot-operated check valve
circuit that prevents cylinder creep.

Figure 8-69. Blocked center directional valve, cylinder creeping forward.

The circuit in Figure 8-70 shows a horizontally mounted, non-leaking cylinder,

positively locked in place any time the directional centers. When using an on-off type
solenoid valve, a fast moving cylinder stops abruptly when the directional valve
centers. Use a proportional valve with ramp timers to decelerate the actuator and
eliminate shock damage.

Figure 8-70. Pilot-operated check circuit at rest with pump running.

Notice the directional valve has A and B ports open to tank in the center condition.
This center condition allows pilot pressure to drop and the pilot-operated check
valves to close. Using a directional valve with blocked A and B ports in center
condition, may keep the pilot-operated check valves open and allow cylinder creep. If
it is only necessary to keep the cylinder from moving in one direction, one pilotoperated check valve will suffice.
When solenoid A1 on the directional valve shifts, as seen in Figure 8-71, the cylinder
extends. Pump flow to the cylinder cap end builds pressure in the pilot line to the rod
end of the pilot-operated check valve, causing it to fully open. The pilot-operated
check valve in the line to the cap end opens by pump flow like any check valve.
Energizing and holding a directional valve solenoid causes the cylinder to move. Pilot
operated check valves positively lock the cylinder but are invisible to the electric
control circuit.

Figure 8-71. Pilot-operated check circuit with cylinder extending.

When solenoid B on the directional valve shifts, as seen in Figure 8-72, the cylinder
retracts. Pump flow to the cylinder rod end builds pressure in the pilot line to the cap
end of the pilot-operated check valve, causing it to fully open. The pilot-operated
check valve in the line to the rod end opens by pump flow like any check valve.
Energizing and holding a directional valve solenoid causes the cylinder to move.

Figure 8-72. Pilot-operated check circuit with cylinder retracting.

The following will describe how pilot-operated check valves can cause problems in
some applications.
Pilot-operated check valves
Figure 8-73 shows how using a pilot-operated check valve to keep a heavy platen
from drifting can cause problems.

Figure 8-73. Pilot-operated check valve on running away load, at rest, pump running.

When a cylinder has a load, trying to extend it causes load-induced pressure. In the
example cited, a 15,000-lb platen pulling against a 26.51 square inch rod end area
gives a 566 psi load-induced pressure. This load-induced pressure holds against the
poppet in the pilot-operated check valve, forcing it closed. The pilot piston must have
sufficient pressure to open the poppet with 566 psi pushing against it. The pilot
piston on most pilot-operated check valves has an area that is three to four times that
of the poppet. This means it will take approximately 141-188 psi at the cap end
cylinder port to open the poppet for reverse flow.
When the directional valve shifts, starting the cylinder forward, as shown in Figure
8-74,pressure in the cap end cylinder port starts climbing to 150 psi. At about 150 psi
the poppet in the pilot-operated check valve opens and allows oil from the cylinder
rod end a free flow path to tank. The cylinder immediately runs away, pressure in
cylinder cap port drops, the pilot-operated check valve closes fast and hard, and the
cylinder stops abruptly. When the pilot-operated check valve closes, pressure at the
cap end cylinder port again builds to 150 psi, opening the check valve, and the
process starts again. A cylinder with these conditions falls and stops all the way to
the work unless it meets enough resistance to keep it from running away.

Figure 8-74. Pilot-operated check valve on running away load, cylinder extending, free fall.

With this circuit, system shock very quickly damages piping, cylinders, and valves.
Adding a flow control between the cylinder and pilot-operated check valve is one way
to keep it from running away. However, the restriction could cause fluid heating and
slow cycling, and would need frequent adjustment to maintain optimum control.
Placing a flow control after the pilot-operated check valve causes backpressure
against its pilot piston and could keep it from opening at all. With the flow control
after the pilot-operated check valve, use one with an external drain. When there is
much backpressure on the outlet of a pilot-operated check valve, it is best to use one
with an external drain.
It is best to control the cylinder shown here with a counterbalance valve. See chapter
five for the different types of counterbalance circuits.
Even with some spool type counterbalance valves, the cylinder still drifts. Adding an
externally drained pilot-operated check valve between the counterbalance valve and
the cylinder holds it stationary. The counterbalance valve keeps the cylinder from
running away no matter the flow variations, while the pilot-operated check valve
holds it stationary when stopped.

Figure 8-75. Pilot-operated check valve on running away load, cylinder stopping on closed P.O. check.

A pilot-operated check valve with the decompression feature would not help in this
circuit.
Figures 8-76 and 8-78 show another possible problem using a pilot-operated check
valve to keep a vertical down-acting cylinder from drifting. The cylinder in this
example has a heavy weight pulling against the rod side. A load induced pressure of
1508 psi plus 142 psi from pilot pressure acts against the poppet in the pilot-operated
check valve. This requires a high pilot pressure to open the pilot-operated check
valve.

Figure 8-76. Pilot-operated check valve on running away load, cylinder just starting to extend.

It requires approximately 500 psi pilot pressure to open the pilot-operated check
valve with 1650 psi against the poppet. As pilot pressure builds to open the poppet, it
also pushes against the full piston area of the cylinder. This cylinder has nearly twice
the area on the cap side as the rod side, so every 100 psi on the cap side gives about
200 psi on the rod side. As pilot pressure builds to the 500 psi required, pressure
against the poppet in the pilot-operated check valve increases at twice the rate.
Figure 8-77 shows the start of this condition.

Figure 8-77. Pilot-operated check valve on running away load, cylinder still trying to extend.

In Figure 8-77, the cylinder rod end pressure is at 300 psi, which adds 570 psi to the
1508 psi load-induced pressure. The extra hydraulic pressure pushes harder against
the pilot-operated check valve poppet, making pilot pressure increase even more.
As pilot pressure increases, down force and rod end pressure escalates also. In Figure
8-78, rod end pressure is at 3565 psi because pilot pressure continues to climb. In
the situation shown here, it is obvious the relief valve will open before reaching a
pilot pressure high enough to open the pilot-operated check valve. Even if pilot
pressure could go high enough to open the pilot-operated check valve, the cylinder
runs away and stops.

Figure 8-78. Pilot-operated check valve on running away load, cylinder still trying to extend.

A pilot-operated check valve with a decompression poppet would not help in this
situation. Flow from the small decompression poppet is not enough to handle
cylinder flow. The cylinder would extend with a decompression poppet, but at a very
slow rate.
It is best to control the cylinder in this example with a counterbalance valve. See
chapter five for the different types of counterbalance circuits.
Even with some spool type counterbalance valves, the cylinder still drifts. Adding an
externally drained pilot-operated check valve between the counterbalance valve and
the cylinder will hold it stationary. The counterbalance valve keeps the cylinder from
running away no matter the flow variations, while the pilot-operated check valve
holds it stationary when stopped.
Shown are circuits that require a pilot-operated check valve to have external drain
and/or decompression capabilities.
A standard pilot-operated check valve circuit usually has minimum backpressure at
the reverse flow outlet port. If there is a restriction causing high backpressure in the
reverse flow outlet port, a standard valve may not open when applying pilot pressure.
The reason this might happen is the pilot piston sees backpressure from the reverse
flow outlet port. If the pilot-operated check valve poppet has load induced pressure
holding it shut, plus reverse flow outlet port backpressure opposing the pilot piston,
there is not enough pilot piston force to open the check poppet.
If the reverse flow outlet port backpressure cannot be eliminated, then specify a
pilot-operated check valve with an external drain. Pipe the external drain to a low or

no pressure line going to tank. With an external drain pilot-operated check valve, the
pilot piston usually opens the check poppet to allow reverse flow.

Figure 8-79. Pilot-operated check valve circuit with external drain function at rest, pump running.

The schematic drawing in Figure 8-79 shows a cylinder with pilot-operated check
valves at each port and meter out flow controls downstream of the reverse flow outlet
port. If this circuit did not have externally drained pilot-operated check valves, the
cylinder would operate in jerks or not at all when the directional valve shifts.
Backpressure from the flow controls can push the pilot piston closed and stop the
cylinder, then pressure would drop and it would start again. This oscillating
movement would continue until the cylinder competes its stroke. With externally
drained pilot-operated check valves, the cylinder is easy to control at any speed.
Placing the flow controls in Figure 8-79 between the cylinder ports and the pilotoperated check valve eliminates backpressure. This move eliminates the need for
externally drained pilot-operated check valves.
In Figure 8-80, a running away load had a drifting problem with only the
counterbalance valve installed. Adding a pilot-operated check valve in front of the
counterbalance valve stopped cylinder drifting. Using a decompression poppet made
it easy to open the main check poppet against the high load induced pressure. The
decompression poppet releases trapped fluid in the piping between the pilotoperated check valve and the counterbalance valve allowing the main check poppet
to open.

Figure 8-80. Pilot-operated check on running away load with external drain and decompression poppet
with P.O. check for no leak holding, counterbalance valve for smooth control of the extend stroke at rest,
with pump running.

Notice the pipe between the pilot-operated check valve and the counterbalance valve
is at zero psi while the cylinder is held retracted. This pressure would have been
about 1200 psi while the cylinder was retracting, but quickly drops to zero when the
directional valve centers. The reason for this pressure drop is leakage past the
counterbalance valve spool, which is the reason for adding the pilot-operated check
valve.
If the pilot-operated check valve did not have an external drain, backpressure from
the counterbalance valve can force it shut when the cylinder starts moving. The
external drain and decompression features are both necessary in this holding circuit.

Placing the pilot-operated check valve in the line after the counterbalance valve
would require neither an external drain nor decompression feature. However, the
reason for installing the pilot-operated check valve was to stop drifting. With the
pilot-operated check valve after the counterbalance valve, the counterbalance valve
must have an external drain. An external drain indicates there is internal leakage, so
the drift problem may decrease -- but would not go away.