7-Directional Control Valves

Lesson 5: Directional Control Valves
Lesson 5: Directional Control Valves
Basic Hydraulic Systems

• Hydraulic Tank
• Hydraulic Fluids
• Hydraulic Pumps and Motors
• Pressure Control Valves
• Directional Control Valves
• Flow Control Valves
• Cylinders
Introduction
Directional control valves are used to direct oil into separate circuits
of a hydraulic system. The maximum flow capacity and the pressure
drop through the valve are the first considerations. Directional
control valves may be interfaced with manual, hydraulic, pneumatic
and electronic controls. These factors are mostly determined during
the initial system design.
Objectives
Upon completion of this lesson the student will:
1. State the function of the manual spool type control valve, the
rotary type control valve and the solenoid actuated control
valve.
2. State the function of the simple check valve, the pilot
operated check valve and the shuttle valve
3. Identify the ISO symbols for the various directional control
valves.
Unit 3 3-5-2 Hydraulic Fundamentals
Lesson 5
Directional Control Valve

The directional control valve is use to direct the supply oil to the
actuator in a hydraulic system.
The valve body is drilled, honed and sometime the bore is heat treated.
The inlet and outlet ports are drilled and threaded. The valve spool is
machined from high grade steel. Some valve spools are heat treated,
ground to size and polished. Other valve spools are chrome plated,
ground to size and polished. The valve body and valve spool are then
mated in assembly to the design specifications. When assembled, the
valve spool is the only part that moves.
VALVE BODY
SPOOL GROOVE
VALVE BORE SPOOL LANDS
Fig. 3.5.1 Valve Spool
Valve Spool
The valve spool (Figure 3.5.1) consist of lands and groves. The spool
lands block the oil flow through the valve body. The spool groves
allow oil to flow around the spool and through the valve body.
The position of the spool when not activated is called the "normal"
position.
When an "open center" valve is in the normal position, the supply oil
flows through the valve and back to the tank. When a "close center"
valve is in the normal position, the supply oil is blocked by the valve
spool.
Lesson 5
FROM FROM
CYLINDER FROM CYLINDER
HEAD END PUMP ROD END
VALVE VALVE
SPOOL BODY
LOAD
CHECK
VALVE TO
TO
TANK TANK
TO TANK
Fig. 3.5.2 Directional Control Valve in HOLD
Open Center Directional Control Valve in HOLD Position

Figure 3.5.2 shows a cutaway diagram of a typical open center
directional control valve in the HOLD position.
In the HOLD position, the pump oil flows into the valve body,
around the valve spool and returns to the tank. The pump oil also
flows to the load check valve. The passage behind the load check is
filled with blocked oil. The blocked oil and the load check valve
spring keep the load check valve closed. The valve spool also blocks
the oil in the line to the rod end and the head end of the cylinder.
FROM FROM
VALVE VALVE
SPOOL BODY
LOAD
CHECK
VALVE TO
TO
TANK TANK
TO TANK
Fig. 3.5.3 Directional Control Valve RAISED
Open Center Directional Control Valve in RAISE Position

Figure 3.5.3, shows the valve spool at the instant the spool is moved
to the RAISE position.
When the valve spool is moved to the RAISE position, the valve
spool blocks the pump oil flow to the tank. However, pump oil flow
is open to the load check valve. The valve spool also connects the
cylinder head end to the oil behind the load check valve and the
cylinder rod end to the tank passage. The load check valve prevents .
Lesson 5
the oil in the head end of the cylinder from flowing into the
pump oil passage. The blocked pump oil flow causes an
increase in the oil pressure
FROM FROM
VALVE VALVE
SPOOL BODY
LOAD
CHECK
VALVE TO
TO
TANK TANK
TO TANK
Fig. 3.5.4 Raise Position
Open Center Directional Control Valve, RAISE Position

In Figure 3.5.4, the increase in pump oil pressure overcomes the
pressure behind the load check valve (unseats the load check valve).
The pump oil flows pass the load check valve and around the valve
spool to the head end of the cylinder.
The oil in the rod end of the cylinder flows pass the valve spool to
the tank.
ONE TWO THREE

POSITION POSITION POSITION
Fig. 3.5.5 ISO Symbols
Directional Control Valve ISO Symbols

Basic Envelope
The basic valve ISO symbol in Figure 3.5.5 consists of one or more
basic envelopes. The number of envelopes used represents the
number of positions that the valve can be shifted.
Lesson 5
TWO-WAY THREE-WAY FOUR-WAY SIX-WAY
Fig. 3.5.6 Valve Port
Valve Port
Shown in Figure 3.5.6 are the valve ports for attaching working lines.
A valve with two ports is commonly referred to as a two-way valve.
This is not to be confused with a two-position valve shown in Figure
3.5.5. Valves may have as many positions and ports as needed.
However, most valve positions are in the range of one to three and
valve ports in the range of two to six.
FLOW IN FLOW IN PARALLEL CROSS FLOW

ONE EITHER FLOW FLOW BLOCKED
DIRECTION DIRECTION
Fig. 3.5.7 Flow Path
Flow Path
In Figure 3.5.7, the lines and arrows inside the envelopes are used
basically to represent the flow paths and directions between ports.
Lesson 5
A B
CLOSED CENTER
P T
A B
TANDEM CENTER
(CATERPILLAR
OPEN CENTER) P T
A B
OPEN CENTER
P T
Fig. 3.5.8 Three Position Valve
Three Position Valve

Figure 3.5.8 shows three ISO symbols of the three position valve. In
the three position valve, the center position is the NEUTRAL or
HOLD position. When the valve is not doing work, the valve is
placed in the HOLD position.
Depending on the design of the spool, the center position serves
several purposes.
The ISO symbol at the top represents a closed center valve. When in
the HOLD position, the close center spool blocks all oil flow.
The ISO symbol in the middle represents a tandem center valve.
When in the HOLD position, the tandem center valve blocks oil flow
at A and B but connects the pump to the tank.
The ISO symbol on the bottom represents an open center valve.
When in the HOLD position, the open center valve connects all ports
to the tank.
Lesson 5
TO
TANK
LOWER
CHECK
VALVE TO CYLINDER ROD END
TO CYLINDER HEAD END
FROM
PUMP TO TANK
RAISE
MANUAL CONTROL
Fig. 3.5.9 Six Way Valve
Three Position, Six Way, Open Center, Manual Controlled Valve
Figure 3.5.9, shows a three position, six way, open center, manual
controlled valve in the HOLD position. The pump oil flows around
the valve spool to the tank. The oil in the cylinder is blocked at the
control valve spool.
PILOT OIL
TO
TANK
LOWER
CHECK
VALVE TO CYLINDER ROD END
TO CYLINDER HEAD END
FROM
PUMP TO TANK
RAISE
PILOT CONTROL
PILOT OIL
Fig. 3.5.10 Six Way Valve
Six Way Valve
Three Position, Six Way, Close Center, Pilot Controlled Valve
Figure 3.5.10 shows a three position, six way, close center, pilot
controlled valve. In the HOLD position, all oil flow is blocked at the
control valve spool.
Lesson 5
SOLENOID MANUAL PUSHBUTTON PEDAL

ACTUATOR ACTUATOR ACTUATOR ACTUATOR
SPRING PUSH-PULL LEVER AIR OIL

MECHANICAL DETENTED
ACTUATOR ACTUATOR
Fig. 3.5.11 Directional Control Valve Actuator
Directional Control Valve Actuator

Figure 3.5.11 shows the ISO symbols for various directional control
valve actuators.
ROD END TO TANK ROD END TO TANK
PORT PORT PORT PORT

VALVE VALVE
CHANNELS
BODY BODY
CHANNELS
PLUG PLUG
PORT PORT
PORT PORT
FROM PUMP HEAD END
FROM PUMP HEAD END
Fig. 3.5.12 Rotary Valve
Rotary Valve
The rotary valve (Figure 3.5.12) consists of a round stem with
passages or channels. The channels in the stem connect with the
ports in the valve body. Instead of shifting to the right or to the left,
the valve rotates.
In the diagram on the left, the valve connects the pump to the rod end
of the cylinder. The oil in head end flows to the tank. When the
valve is rotated 90 degrees, the pump is connected to the head end
and the oil in the rod end flows to the tank.
The rotary valve shown is a four-way valve. However, rotary valves
may also be two-way or three-way. The rotary valve is used in low
pressure operations.
INSTRUCTOR NOTE: At this time, perform Lab 3.5.1
Lesson 5
TO FROM
IMPLEMENT IMPLEMENT
FROM TO
PUMP PUMP
Fig. 3.5.13 Check Valve
Check Valve
The purpose of a check valve is to readily permit oil flow in one
direction, but prevent (check) oil flow in the opposite direction. The
check valve is sometimes called a "one way" check valve.
Most check valves consist of a spring and a tapered seat valve as in
Figure 3.5.13 above. However, a round ball is sometimes used
instead of the tapered seat valve. In some circuits, the check valve
may be free floating (has no spring).
In the valve on the left, when the pump oil pressure overcomes the
oil pressure in back of the check valve plus the check valve slight
spring force, the check valve opens and allows the oil to flow to the
implement.
In the valve on the right, when the pressure of the pump oil is less
than the oil pressure in the implement, the check valve closes and
prevents implement oil flow back through the valve.
Lesson 5
Pilot Operated Check Valve

The pilot operated check valve differs from the simple check valve in
that the pilot operated check valve allows oil flow through the valve
in the reverse direction.
PILOT VALVE PILOT ROD TO

OIL CHAMBER VALVE CYLINDER
PILOT
OIL
CHECK VALVE
FROM CONTROL
VALVE
Fig. 3.5.14 Forward Flow
Forward Flow
Figure 3.5.14 shows a pilot operated check valve. The pilot operated
check valve consist of a check valve, a pilot valve and a rod. The
pilot operated check valve allows free flow from the control valve to
the cylinder.
FROM
PILOT VALVE PILOT ROD CYLINDER
OIL CHAMBER VALVE
PILOT
OIL
CHECK VALVE
TO CONTROL
VALVE
Fig. 3.5.15 Flow Blocked
Flow Blocked
When oil flow from the control valve cease, the check valve seats as
shown on the right of Figure 3.5.15. The oil flow from the cylinder
to the control valve is blocked at the check valve.
The pilot operated check valve is most often used in operations where
load drift is a problem. The pilot operated check valve allows load
drift to be held to a very close tolerance.
Lesson 5
FROM
PILOT VALVE PILOT ROD CYLINDER
OIL CHAMBER VALVE
PILOT
OIL
TO CONTROL CHECK VALVE

VALVE
Fig. 3.5.16 Reverse Flow
Reverse Flow
The valve in Figure 3.5.16, shows oil flow from the cylinder to the
control valve.
When flow is required, pilot oil is sent to the pilot valve oil chamber.
Pilot oil pressure moves the pilot valve and rod to the right and
unseats the check valve. The cylinder oil flows through the check
valve to the control valve and then to the tank.
The pressure ratio between the load pressure and the pilot pressure is
designed into the valve. The valve used on the Explorer training unit
has a pressure ratio of 3:1. The pressure needed to open the check
valve is equal to one-third of the load pressure. A load pressure of
4134 kPa (600 psi) requires a pilot pressure of 1378 kPa (200 psi) to
open the check valve.
Lesson 5
A B
CHECK VALVE (OPEN) CHECK VALVE (CLOSED)
PILOT
CIRCUIT 1 CIRCUIT 2
C
D
CIRCUIT 3
PILOT OPERATED
SHUTTLE VALVE CHECK VALVE
(RESOLVER VALVE)
Fig. 3.5.17 Check Valve ISO Symbols
Check Valve ISO Symbols

In Figure 3.5.17, symbols A and B represents the simple check valve
in the OPEN and CLOSE positions.
Symbol C represent the shuttle valve. The shuttle (resolver) valve
allows two separate circuits to supply oil to a third circuit while
keeping the two separate circuits isolated from each other.
Symbol D represents the pilot operated check valve.
Lesson 5
FROM TO
CYLINDER CYLINDERS
TANK OIL TANK OIL
Fig. 3.5.18 Make-up Valve
Make-up Valve
The make-up valve in Figure 3.5.18, looks similar to the check valve.
The makeup valve is normally positioned in the circuit between the
implement and the tank. During normal operations, the pump or
cylinder oil fills the area behind the make-up valve. The pressure in
the cylinder keeps the valve CLOSED. When the cylinder pressure is
approximately 14 kPa (2 psi) lower than the tank pressure, the make-
up valve will OPEN. The tank oil bypasses the pump and flows
directly through the make-up valve to the cylinder.
The make-up valve is used to prevent cavitation. For example, when
a loader bucket is RAISED and the operator moves the control to the
FULLY LOWER position, the gravitational force on the bucket is
transmitted through the cylinder piston to the return oil. The
increased pressure on the return oil increases the flow from the
cylinder. When the cylinder piston displaces the return oil faster than
the pump can send oil to displace the piston, a vacuum is formed in
the cylinder and lines. A vacuum can cause the cylinder and lines to
cavitate. When the pressure in the cylinder and lines decreases to 14
kPa (2 psi) less than tank pressure, the make-up valve opens and
allows tank oil to flow through the make-up valve to the lines and
cylinder. This procedure prevents cavitation in the cylinder and lines.
Makeup Valve ISO Symbol
The operation (function) of the make-up valve and the check valve is
the same. Therefore, the ISO symbol for the make-up valve is the
same as the ISO symbol for the check valve.
INSTRUCTOR NOTE: At this time, perform Lab 3.5.2 and Lab
3.5.3
Lesson 5
SOLENOID ACTUATED CONTROL VALVES

Solenoid Actuator
In a solenoid actuator, an electro-magnetic field moves an armature
which moves a push pin. The push pin moves the valve spool.
The two most popular solenoid actuators are the air gap and the wet
armature.
ELECTRO-MAGNETIC
FIELD
COVER
MANUAL
OVERRIDE
PUSH
PIN
COIL ARMATURE
Fig. 3.5.19 Air Gap Solenoid
Air Gap Solenoid

An air gap solenoid is shown in Figure 3.5.19. When the coil is
energized, an electro-magnetic field is created. Such a field develops
whenever electricity flows through a wire. When the wire is straight,
the field is relatively weak. When the wire is wound into a coil, the
electro-magnetic field becomes much stronger. The field takes a
circular shape around the coil. The higher the number of turns in the
coil, the stronger the field.
When the flow of electricity through the coil remains constant, the
electro-magnetic field acts very much like the field of a permanent
bar magnet. The electro-magnetic field attracts the armature. The
armature moves a push pin and the push pin moves the valve spool in
the control valve.
The air gap solenoid is protected by a cover. The air gap solenoid
also has a "manual override" feature. The manual override allows the
valve to be activated when the solenoid is defective or disabled. A
small metal pin is located in the cover. The pin is positioned directly
in line with the armature. When the pin is pushed into the cover, the
pin mechanically moves the armature. The armature moves the push
pin which shifts the spool.
Lesson 5
PUSH PIN TUBE
HYDRAULIC
MANUAL
FLUID
OVERRIDE
FRAME COIL ARMATURE
Fig. 3.5.20 Wet Armature Solenoid
Wet Armature Solenoid

The wet armature solenoid (Figure 3.5.20) is a relatively new arrival
on the hydraulic scene.
The wet armature solenoid consist of a rectangular frame, coil, tube,
armature, push pin and manual override. The coil and rectangular
frame is encapsulated in plastic. The tube fits into a hole that runs
through the coil center and two sides of the frame. The armature is
housed within the tube and is bathed with hydraulic fluid from the
directional valve. The hydraulic fluid is a better conductor of the
electro-magnetic field than air. Therefore, the wet armature solenoid
works with greater force than the air gap solenoid.
When the coil is energized, an electro-magnetic field is created. The
electro-magnetic field moves the armature. The armature moves a
push pin and the push pin moves the valve spool in the control valve.
In the wet armature solenoid, the manual override is located on the
end of the tube which houses the armature and the push pin. The
manual override is used to check movement of the directional valve
spool. If the solenoid fails because the spool jammed, the spool
movement can be checked by pushing in the manual override. The
manual override may also be used to cycle the actuator without
energizing the complete electrical control system.
Lesson 5
A B
P
T
T A P B
Fig. 3.5.21 Two Position 4-Way Directional Control Valve
Solenoid Controlled, Spring Offset, Pilot Operated, Two Position,

4-way Directional Control Valve
Figure 3.5.21, shows a Solenoid Controlled, Spring Offset, Pilot
Operated, Two Position, 4-way Directional Control Valve.
The solenoid controlled, spring offset, pilot operated, two position,
directional control valve is not frequently equipped with two
solenoids. The second solenoid is considered an unnecessary
expense and an additional solenoid to worry about in the system.
The solenoid is used to shift the pilot valve spool. The pilot valve
spool is returned to its original position by a spring. When a system
is designed for large oil flow, a large directional valve is required. A
substantial force is needed to shift the large valve spool. The
solenoid needed to generate that amount of force would be quite
large. In valves of this type, a small solenoid controlled pilot valve is
positioned on top of the larger main valve spool. When shifting is
required, pressurized oil flows from the small solenoid controlled
pilot valve to either side of the larger valve spool.
Lesson 5
SOLENOID CONTROLLED
SOLENOID PILOT VALVE SOLENOID
A B
P
T
T A P B
Fig. 3.5.22 Three Position 4-way Directional Control Valve
Solenoid Controlled, Pilot Operated, Three Position,

4-way Directional Control Valve
Figure 3.5.22 shows a Solenoid Controlled, Pilot Operated, Three
Position, 4-way Directional Control Valve.
The pilot valve is controlled by two solenoid valves. The pilot valve
also has a spring located at each end of the valve spool. When
neither solenoid is energized, the pilot valve spool springs hold the
pilot valve spool in the CENTER position. When the pilot valve is in
the CENTER position, pilot oil flow to the larger control valve is
blocked. The springs in the three position directional control valve
return the control spool to the center position.
Spring centering is the most common means of centering a
directional control valve spool. The directional control valve has a
spring located at each end of the valve spool. When pilot oil pressure
is applied to either end of the directional valve spool, the valve spool
moves and compresses the spring on the opposite end. When the
pilot oil pressure is removed, the spring returns the directional control
spool to the center position.
Lesson 5
Solenoid Failure
Most solenoid actuator failures occur when valves are stuck. The
stuck valve spool prevents the armature from closing properly. The
most likely cause of a stuck valve spool is contamination.
Contaminant such as silt, metal chips, and other particles may
become lodged between the spool and bore causing the spool to stick.
Also, oxidized oil particles can create a gooey varnish which clogs
the clearance between the spool and bore walls and cause the spool to
stick to the bore. Silt, metal chips, and other contaminating particles
can be removed by installing a filter. The varnish build-up can be
removed by washing the valve in lacquer thinner. The proper oil and
filter change intervals can help to eliminate most of this type
problems.
When the valve is stuck and the solenoid is energized, the solenoid
coil receives a constant high flow of current that generates excessive
heat. The solenoid is not designed to dissipate the excessive heat and
the coil burns out. Overheating problems most often occur during
periods of high ambient (environmental) temperatures, or system low
voltage.
Problems with solenoid failure due to high ambient temperatures may
be controlled by increasing the air flow across the solenoid. The
temperature of the hydraulic oil can be lowered to allow more heat to
be drawn from the solenoid through the hydraulic system.
Sometimes, a different valve design may be required when operating
during very hot weather. Some arrangement must be made to allow
the system to operate at a lower temperature.
When the voltage to the coil is too low, the electro-magnetic field is
not sufficiently strong to attract the armature. Just as when the spool
is stuck, the current continues flowing through the coil. The constant
flow of current generates the excessive heat.
Other factors also affect the proper operation and life expectancy of
the solenoid actuator. The solenoid actuator may fail when cycled
excessively, when short-circuited, or when operated with an incorrect
electrical supply (wrong frequency, wrong voltage).
Lesson 5
A B
P T
Fig. 3.5.23 Two Position, 4-way Pilot Valve
Spring Offset, Solenoid Controlled, Two Position, 4-Way Pilot

Valve
In the ISO symbol in Figure 3.5.23, the spring offset pilot valve is
shown in its normal position. The pump oil flows to A and the oil in
B flows to the tank.
When the solenoid is energized, the solenoid moves the valve against
the spring. The pump oil then flows to B and the oil in A flows to the
tank.
A B
P T
Fig. 3.5.24 Three Position, 4-way Control Valve
Solenoid Controlled Pilot Operated, Spring Centered,

Three Position, 4-Way, Closed-Centered Control Valve
In the ISO symbol in Figure 3.5.24, the solenoid controlled pilot

operated, spring centered, three position, 4-way, closed-centered
control valve is shown in its normal position. All four ways are
blocked at the valve. When the solenoid on the right is energized, the
pump oil flows to B and the oil in A flows to the tank. When the
solenoid on the left is energized, the pump oil flows to A and the oil
in B flows to the tank.
INSTRUCTOR NOTE: At this time, perform Lab 3.5.4
Unit 3 -1- Hydraulic Fundamentals
Instructor Copy Lab 3.5.1
Instructor Copy: Lab 3.5.1

Name _________________________
ROD END HEAD END

GAUGE GAUGE
SYSTEM
PRESSURE
GAUGE
SYSTEM
RELIEF 2
VALVE
BACKUP P A
RELIEF
VALVE 1 1 T B
PUMP
CYLINDER
MANUAL
DIRECTIONAL
CONTROL VALVE
TANK
Fig. 3.5.25 Circuit

LAB 3.5.1: DIRECTIONAL CONTROL VALVE
Purpose
To install and operate a directional control valve in a simple circuit.
Materials needed
1. Basic Hydraulic Training Unit
Procedure
1. Mount the manual valve to the horizontal component mounting rack.
To mount the valve, first loosen the wing nuts about half way. Slide the carriage bolts into the
grooves on the mounting rack. Move the valve to where you can operate the lever comfortably.
Tighten the wing nuts so that the valve is securely in place.
2. Construct the circuit in Figure 3.5.25.
4. Adjust system pressure to 5856 kPa (850 psi).
3. Turn ON the training unit.
5. With the control lever in the NEUTRAL position, read the pressure gauges. Record the pressure
readings below.
System pressure gauge: approximately 517 kPa - 689 kPa (75 psi - 110 psi) (line resistances)
Rod End pressure gauge: 0 kPa (0 psi)
Head End pressure gauge: 0 kPa (0 psi)
LAB 3.5.1: DIRECTIONAL CONTROL VALVE (continued)
6. Retract the cylinder rod until the rod stops moving. Continue to hold the control lever in the
retract position and read the pressure gauges. Record the pressure readings below.
System pressure gauge: 5856 kPa(850 psi)
Rod End pressure gauge: 5856 kPa(850 psi)
7. Extend the cylinder rod until the rod stops moving. Continue to hold the control lever in the
rod extend position and read pressure gauges. Record the pressure readings below.
System pressure gauge: 5856 kPa(850 psi)
Head End pressure gauge: 5856 kPa(850 psi)
8. State the differences in the three sets of readings.

The readings in Step 5 shows the valve in its neutral position with the pump port connected
to the tank. The resistances shown is the resistances of the line and control valve. Ports A
and B are blocked. Ports A and B have not been pressurized.
The readings in Step 6 shows the cylinder fully retracted. The oil flow into the cylinder is
blocked at piston. The oil pressure has increased and opened the system relief valve. Ports P
and A are connected and the pressures are equal. Port B is connected to the tank.
The readings in Step 7 shows the cylinder fully extended. The oil flow into the cylinder is
blocked at the piston. The oil pressure has increased and opened the system relief valve.
Ports P and B are connected and the pressures are equal. Port A is connected to the tank.
9. Turn OFF the training unit and disconnect the hoses.
Student Copy Lab 3.5.1
Student Copy: Lab 3.5.1

Name _________________________
ROD END HEAD END

GAUGE GAUGE
SYSTEM
PRESSURE
GAUGE
SYSTEM
RELIEF 2
VALVE
BACKUP P A
RELIEF
VALVE 1 1 T B
PUMP
CYLINDER
MANUAL
DIRECTIONAL
CONTROL VALVE
TANK
Fig. 3.5.25 Circuit
LAB 3.5.1: DIRECTIONAL CONTROL VALVE
Purpose
To install and operate a directional control valve in a simple circuit.
Materials needed
Procedure
1. Mount the manual valve to the horizontal component mounting rack.
To mount the valve, first loosen the wing nuts about half way. Slide the carriage bolts into the
grooves on the mounting rack. Move the valve to where you can operate the lever comfortably.
Tighten the wing nuts so that the valve is securely in place.
5. With the control lever in the NEUTRAL position, read the pressure gauges. Record the pressure
readings below.
System pressure gauge:
Rod End pressure gauge:
Head End pressure gauge:
LAB 3.5.1: DIRECTIONAL CONTROL VALVE (continued)
6. Retract the cylinder rod until the rod stops moving. Continue to hold the control lever in the
retract position and read the pressure gauges. Record the pressure readings below.
7. Extend the cylinder rod until the rod stops moving. Continue to hold the control lever in the
rod extend position and read pressure gauges. Record the pressure readings below.


Name _________________________
SYSTEM
PRESSURE 2 1
GAUGE
SIMPLE CHECK
VALVE
SYSTEM 2
RELIEF
VALVE
BACKUP
RELIEF FLOW
VALVE 1 1 METER
PUMP
TANK
Fig. 3.5.26 Circuit
LAB 3.5.2: CHECK VALVE
Purpose
To install and operate a check valve in a simple circuit.
Materials needed
Procedure
1. Construct the circuit given in Figure 3.5.26.
4. Read the system pressure gauge and the flow meter (Reading 1).
5. Record the pressure and flow in the chart in Figure 3.5.27.
READINGS PRESSURE GAUGE FLOW METER
1 517 kPa - 689 kPa (75 psi - 100 psi) 0.9 GPM
2 5856 kPa (850 psi) 0 GPM
Lab. 3.5.27
6. Turn OFF the training unit.

SYSTEM
PRESSURE 1 2
GAUGE
SIMPLE CHECK
VALVE
SYSTEM 2
RELIEF
VALVE
BACKUP
RELIEF FLOW
VALVE 1 1 METER
PUMP
TANK
Fig. 3.5.28 Circuit
LAB 3.5.2: CHECK VALVE (continued)
7. Reverse the check valve as in Figure 3.5.28.

Explain the difference between reading 1 and reading 2.

The pressure in reading 1 shows the resistances to the 0.9 gpm flow through the lines,
check valve and flow meter. The pressure in reading 2 shows that the system relief valve
is open and there is no flow through the lines, check valve and flow meter.

Name _________________________
SYSTEM
PRESSURE 2 1
GAUGE
SIMPLE CHECK
VALVE
SYSTEM 2
RELIEF
VALVE
BACKUP
RELIEF FLOW
VALVE 1 1 METER
PUMP
TANK
Fig. 3.5.26 Circuit
LAB 3.5.2: CHECK VALVE
Purpose
To install and operate a check valve in a simple circuit.
Materials needed
Procedure
1. Construct the circuit given in Figure 3.5.26.
READINGS PRESSURE GAUGE FLOW METER
Fig. 3.5.27

SYSTEM
PRESSURE 1 2
GAUGE
SIMPLE CHECK
VALVE
SYSTEM 2
RELIEF
VALVE
BACKUP
RELIEF FLOW
VALVE 1 1 METER
PUMP
TANK
Fig. 3.5.28 Circuit
LAB 3.5.2: CHECK VALVE (continued)
7. Reverse the check valve as in Figure 3.5.28.

Explain the difference between reading 1 and reading 2.

__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________

Name _________________________
3
SYSTEM
PRESSURE 1 2
GAUGE
PILOT CHECK
VALVE
SYSTEM
RELIEF 2
VALVE
BACKUP
RELIEF FLOW
VALVE 1 1 METER
PUMP
TANK
Fig. 3.5.29 Circuit
LAB 3.5.3: PILOT OPERATED CHECK VALVE CIRCUIT
Purpose
To install and operate a pilot operated check valve in a simple circuit.
Materials needed
Procedure
1. Construct the circuit shown in Figure 3.5.29
4. Read the pressure gauge and flow meter (Reading 1).
5. Record the information on the chart in Figure 3.5.30.
READING FLOW RATE SYSTEM OPENING

PRESSURE PRESSURE
1 0 GPM 5856 kPa (850 psi)
2 0.9 GPM 2067 kPa (300 psi) 930 kPa (135 psi)
3 0 GPM 4134 kPa (600 psi) 520 kPa (75 psi)
4 0.9 GPM 4134 kPa (600 psi) 1520 kPa (220 psi)
Fig. 3.5.30 Chart

OPENING
PRESSURE
3
2 1
SYSTEM
PRESSURE 3
REDUCING
PRESSURE
GAUGE
VALVE 1 2
PILOT CHECK
VALVE
SYSTEM 2
RELIEF
VALVE
BACKUP
RELIEF FLOW
VALVE 1 1 METER
PUMP
TANK
Fig. 3.5.31 Circuit
LAB 3.5.3: PILOT OPERATED CHECK VALVE CIRCUIT (Continued)
7. Reconstruct the circuit as shown in Figure 3.5.31.

8. Turn the adjustment on the pressure reducing valve fully counter-clock wise.
10. Set system pressure to 2067 kPa (300 psi).
11. Slowly turn the adjustment on the pressure reducing valve clockwise until flow is seen through
the flow meter.
12. Read the pressure gauges and the flow meter (Reading 2).
14. Turn OFF the training unit for two minutes.
15. Turn the pressure reducing valve adjustment one turn counter-clockwise.
17. Adjust the system pressure to 4134 kPa (600 psi).
the flow meter.
Questions:
1. Does the pilot operated check valve opening pressure equal to approximately one third the
system pressure?
X Yes No
2. Explain the difference between the non-pilot check valve and the pilot check valve.
The non-pilot check valve allows free flow in one direction while blocking all flow in the
opposite direction.
The pilot check valve allows free flow in one direction. Also, under select conditions, a third
port is used to open the check valve and allow flow in the opposite direction.

Name _________________________
SYSTEM
PRESSURE 1 2
GAUGE
PILOT CHECK
VALVE
SYSTEM
RELIEF 2
VALVE
BACKUP
RELIEF FLOW
VALVE 1 1 METER
PUMP
TANK
Fig. 3.5.29 Circuit
LAB 3.5.3: PILOT OPERATED CHECK VALVE CIRCUIT
Purpose
To install and operate a pilot operated check valve in a simple circuit.
Materials needed
Procedure
1. Construct the circuit shown in Figure 3.5.29
4. Read the pressure gauge and flow meter (Reading 1).
READING FLOW RATE SYSTEM OPENING

PRESSURE PRESSURE
Fig. 3.5.30 Chart

OPENING
PRESSURE
3
2 1
SYSTEM
PRESSURE 3
REDUCING
PRESSURE
GAUGE
VALVE 1 2
PILOT CHECK
VALVE
SYSTEM 2
RELIEF
VALVE
BACKUP
RELIEF FLOW
VALVE 1 1 METER
PUMP
TANK
Fig. 3.5.31 Circuit
7. Reconstruct the circuit as shown in Figure 3.5.31.

8. Turn the adjustment on the pressure reducing valve fully counter-clock wise.
10. Set system pressure to 2067 kPa (300 psi).
the flow meter.
14. Turn OFF the training unit for two minutes.
15. Turn the pressure reducing valve adjustment one turn counter-clockwise.
17. Adjust the system pressure to 4134 kPa (600 psi).
the flow meter.
LAB 3.5.3: PILOT OPERATED CHECK VALVE CIRCUIT (continued)
Questions:
1. Does the pilot check valve opening pressure equal to approximately one third the system
pressure?
Yes No
2. Explain the difference between the non-pilot check valve and the pilot check valve.

Name _________________________
ROD END HEAD END

GAUGE GAUGE
SYSTEM
PRESSURE
GAUGE
SYSTEM
RELIEF
2
VALVE
BACKUP P A
RELIEF
VALVE 1 1
T B
PUMP
CYLINDER
SOLENOID
CONTROL
VALVE
TANK
Fig. 3.5.32 Circuit
LAB 3.5.4 SOLENOID ACTUATED DIRECTIONAL CONTROL VALVE
Purpose
To install and operate a solenoid actuated directional control valve in a simple circuit.
Materials needed
Procedure
2. Adjust system pressure to 5856 kPa (850 psi)..
4. With the control valve in the NEUTRAL position, read the pressure gauges. Record the
pressure readings below.
System pressure gauge: 5856 kPa (850 psi)
Rod End pressure gauge: 0 PSI
Head End pressure gauge: 0 PSI
5. Depress and hold the switch to retract the cylinder rod. Read the pressure gauge and record the
Head End pressure gauge: 0 PSI
LAB 3.5.4 SOLENOID ACTUATED DIRECTIONAL CONTROL VALVE (continued)
6. Depress and hold the switch to extend the cylinder rod. Read the pressure gauges and record
the pressure readings below.
Rod End pressure gauge: 0 PSI
7. Disconnect the pump electrical power supply and move the solenoid actuated control valve to
reduce the pressure in the hoses.
8. Turn OFF the training unit and connect the pump electrical power supply. Disconnect the
hoses.
Questions:
The readings in Step 4 shows the valve in its neutral position with all ports blocked. The
pump oil is flowing across the relief valve. Ports A and B have not been pressurized.
The readings in Step 5 shows the cylinder fully retracted. The oil flow into the cylinder is
Ports P and A are connected and the pressures are equal. Port B is connected to the tank.
The readings in Step 6 shows the cylinder fully extended. The oil flow into the cylinder is
Ports P and B are connected and the pressures are equal. Port A is connected to the tank.
2. What happens inside the valve when the rod extending solenoid is activated?
When the solenoid is activated, an electromagnetic field is created around the coil. This field
attracts the armature which is connected to the push rod. The push rod moves the valve
spool to a new position. The valve compresses the spring at the opposite end of the spool.
The position of the spool determines the path of oil flow. When the rod is extended, pump
flow is directed to port B during solenoid activation. The oil from port A is simultaneously
returned to the tank.
3. What happens inside the valve when both solenoids are deactivated?
When both solenoids are deactivated, the electromagnetic field collapse around the coil. The
spring, on the opposite end of the spool, moves the spool to the NEUTRAL position. The
spool moves the push rod and armature back to the starting position.
4. How could you tell the valve spool moved without looking at the gauges?
There is an indicator light on the solenoid valve electrical connection which illuminates
when the solenoid is activated. You can also hear the solenoid armature close and the valve
spool move.
Name _________________________

ROD END HEAD END
GAUGE GAUGE
SYSTEM
PRESSURE
GAUGE
SYSTEM
RELIEF
2
VALVE
BACKUP P A
RELIEF
VALVE 1 1
T B
PUMP
CYLINDER
SOLENOID
CONTROL
VALVE
TANK
Fig. 3.5.32 Circuit
LAB 3.5.4 SOLENOID ACTUATED DIRECTIONAL CONTROL VALVE
Purpose
To install and operate a solenoid actuated control valve in a simple circuit.
Materials needed
Procedure
2. Adjust system pressure to 5856 kPa (850 psi)..
4. With the control valve in the NEUTRAL position, read the pressure gauges. Record the
5. Depress and hold the switch to retract the cylinder rod. Read the pressure gauge and record the
LAB 3.5.4 SOLENOID ACTUATED DIRECTIONAL CONTROL VALVE (continued)
6. Depress and hold the switch to extend the cylinder rod. Read the pressure gauges and record
the pressure readings below.
7. Disconnect the pump electrical power supply and move the solenoid actuated control valve to
reduce the pressure in the hoses.
8. Turn OFF the training unit and connect the pump electrical power supply. Disconnect the
hoses.
Questions:
2. What happens inside the valve when the rod extending solenoid is activated?
3. What happens inside the valve when both solenoids are deactivated?
4. How could you tell the valve spool moved without looking at the gauges?
Instructor Copy Quiz 3.5.1
Instructor Copy: Quiz 3.5.1

Name _________________________
DIRECTIONAL CONTROL VALVE QUIZ
1. List two considerations when choosing a directional control valve.

Maximum flow capacity
Pressure drop through the valve
2. Name the part of a directional control valve that moves.
The valve spool
Fill in the blanks
3. The spool lands block the flow of oil through the valve body.
4. The spool groves allows oil to flow around the spool and through the valve body.
5. In the basic valve ISO symbol, the number of envelopes represent the number of positions that
the valve can be shifted.
6. When in the normal position, the supply oil flows through the valve and back to tank. The
valve is an open center valve.
7. When in the normal position, the supply oil flows through the valve is blocked. The valve is a
close center valve.
8. In the basic valve ISO symbol, the lines and arrows inside the envelopes are used basically to
represent the flow path and direction between ports.
DIRECTIONAL CONTROL VALVE QUIZ (continued)
9. Write the correct name below each symbol.
SOLENOID MANUAL PUSHBUTTON PEDAL

SPRING PUSH-PULL LEVER AIR OIL

MECHANICAL DETENTED
ACTUATOR ACTUATOR
10. Draw a lever operated, spring centered, three-position, 4-way, open center, directional control
valve.
11. What is the purpose for having a manual override on a solenoid actuator?
The manual override on a solenoid actuated valve allows the valve to be actuated
when the solenoid is defective or disabled.
12. Describe how a solenoid actuator is used on a 2-position valve.

A single solenoid is used on a 2-position valve to move the spool from normal position
to actuated position. Typically a spring is used to return the spool to its normal
position.
13. Name three conditions that may cause solenoid overheating.

Stuck valves
High ambient temperatures
Low system voltage
14. Describe the operation of a check valve.
The check valve (consisting of a ball or poppet held in place with a light spring) is installed
in series with the oil flow through the circuit. The check valve offers a restriction to oil flow
which causes a slight pressure to develop against the check valve. When the force of the oil
pressure against the valve surface area overcomes the valve spring force and any oil pressure
that may be behind the valve, the check valve is moved off its seat. The oil flows through the
check valve to the remaining circuit.
When the oil flow is reversed, the force is removed from against the check valve spring. The
spring closes the valve and blocks oil flow. The increase in force from the pressure caused
by the blocked oil flow is added to the spring force and keeps the check valve seated.
The check valve allows oil to flow in one direction and blocks oil flow in the opposite
direction.
15. What happens in a circuit when the check valve is installed backwards?
The valve allows flow when the flow is supposed to be blocked and blocks flow when the flow
is supposed to flow freely.
16. In what way does a pilot operated check valve differ from a simple check valve.
The pilot operated check valve differs from the simple check valve in that the pilot operated
check valve allows oil to flow in the reverse direction through the valve.
17. What are pilot ratio and pilot pressure?
Pilot ratio is the ratio between the line pressure behind the check valve and the pilot pressure
required to open the check valve. A 3:1 pilot ratio is typical of most piloted check valves.
Pilot pressure is the supply pressure fed to the pilot port of the valve. The pilot pressure is
used to open the check valve to reverse oil flow.
CIRCUIT 1 CIRCUIT 2
CIRCUIT 3
18. In the shuttle (resolver) valve symbol above, oil may flow:
A. From circuit 1 to circuit 2 D. A and B
B. From circuit 2 to circuit 3 E. B and C
C. From circuit 1 to circuit 3
19. Identify and write the name of the spool valve part in the space provided.
VALVE BORE
SPOOL GROOVE
SPOOL LANDS
20. When the load pressure to pilot pressure ratio is 3:1, what is the minimum pressure required to
open the check valve below.
VALVE BORE
SPOOL GROOVE
SPOOL LANDS
Student Copy Quiz 3.5.1
Student Copy: Quiz 3.5.1

Name _________________________
DIRECTIONAL CONTROL VALVE QUIZ
1. List two considerations when choosing a directional control valve.
2. Name the part of a directional control valve that moves.
3. The block the flow of oil through the valve body.
4. The allows oil to flow around the spool and through the valve body.
5. In the basic valve ISO symbol, the number of envelopes represent the number of that
the valve can be shifted.
6. When in the normal position, the supply oil flows through the valve and back to tank. The
valve is an .
7. When in the normal position, the supply oil flows through the valve is blocked. The valve is
a .
8. In the basic valve ISO symbol, the lines and arrows inside the envelopes are used basically to
represent the .
9. Write the correct name below each symbol.
10. Draw a lever operated, spring centered, three-position, 4-way, open center, directional control
valve.
1. What is the purpose for having a manual override on a solenoid actuator?
12. Describe how a solenoid actuator is used on a 2-position valve.

13. Name three conditions that may cause solenoid overheating.
14. Describe the operation of a check valve.
15. What happens in a circuit when the check valve is installed backwards?
16. In what way does a pilot operated check valve differ from a simple check valve.
17. What are pilot ratio and pilot pressure?

CIRCUIT 1 CIRCUIT 2
CIRCUIT 3
18. In the shuttle valve (resolver) symbol above, oil may flow:
A. From circuit 1 to circuit 2 D. A and B
B. From circuit 2 to circuit 3 E. B and C
C. From circuit 1 to circuit 3
19. Identify and write the name of the spool valve part in the space provided.
20. When the load pressure to pilot pressure ratio is 3:1, what is the minimum pressure required to
open the check valve below.
FROM 6200 kPa
CYLINDER (900 psi)
PILOT
OIL
TO CONTROL
VALVE

7-Directional Control Valves

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Lesson 5: Directional Control Valves

Lesson 5: Directional Control Valves

Basic Hydraulic Systems

Directional Control Valve

VALVE BORE SPOOL LANDS

Fig. 3.5.1 Valve Spool

Fig. 3.5.2 Directional Control Valve in HOLD

Open Center Directional Control Valve in HOLD Position

Fig. 3.5.3 Directional Control Valve RAISED

Open Center Directional Control Valve in RAISE Position

Open Center Directional Control Valve, RAISE Position

ONE TWO THREE

Directional Control Valve ISO Symbols

TWO-WAY THREE-WAY FOUR-WAY SIX-WAY

Fig. 3.5.6 Valve Port

FLOW IN FLOW IN PARALLEL CROSS FLOW

Fig. 3.5.7 Flow Path

Fig. 3.5.8 Three Position Valve

Three Position Valve

Fig. 3.5.9 Six Way Valve

Three Position, Six Way, Open Center, Manual Controlled Valve

Fig. 3.5.10 Six Way Valve

Six Way Valve

Three Position, Six Way, Close Center, Pilot Controlled Valve

SOLENOID MANUAL PUSHBUTTON PEDAL

SPRING PUSH-PULL LEVER AIR OIL

Fig. 3.5.11 Directional Control Valve Actuator

Directional Control Valve Actuator

ROD END TO TANK ROD END TO TANK

PORT PORT PORT PORT

Fig. 3.5.12 Rotary Valve

Fig. 3.5.13 Check Valve

Pilot Operated Check Valve

PILOT VALVE PILOT ROD TO

Fig. 3.5.14 Forward Flow

TO CONTROL CHECK VALVE

CHECK VALVE (OPEN) CHECK VALVE (CLOSED)

Fig. 3.5.17 Check Valve ISO Symbols

Check Valve ISO Symbols

TANK OIL TANK OIL

Fig. 3.5.18 Make-up Valve

SOLENOID ACTUATED CONTROL VALVES

Fig. 3.5.19 Air Gap Solenoid

Air Gap Solenoid

PUSH PIN TUBE

FRAME COIL ARMATURE

Fig. 3.5.20 Wet Armature Solenoid

Wet Armature Solenoid

Fig. 3.5.21 Two Position 4-Way Directional Control Valve

Solenoid Controlled, Spring Offset, Pilot Operated, Two Position,

Fig. 3.5.22 Three Position 4-way Directional Control Valve

Solenoid Controlled, Pilot Operated, Three Position,

Spring Offset, Solenoid Controlled, Two Position, 4-Way Pilot

Fig. 3.5.24 Three Position, 4-way Control Valve

Solenoid Controlled Pilot Operated, Spring Centered,

In the ISO symbol in Figure 3.5.24, the solenoid controlled pilot

Instructor Copy: Lab 3.5.1

ROD END HEAD END

Fig. 3.5.25 Circuit

LAB 3.5.1: DIRECTIONAL CONTROL VALVE (continued)

8. State the differences in the three sets of readings.

Student Copy: Lab 3.5.1

ROD END HEAD END