To: Nancy Myers

From: Jeff Johns

Date: April 20, 2021

Subject: APLED 121- Description/Report

Pilot Operated Relief Valve

Pilot operated relief valves are very useful. Without them, a hydraulic system will not be
able to handle naturally occurring spikes in pressure when cylinders bottom out, or when a
hydraulic motor’s designed torque is exceeded. Pilot operated reliefs keep the pressure in a
system at a manageable level, extending the life of system components and fluid lines. Every
hydraulic circuit should include a pilot operated relief valve!
• Valve Body: This is the housing for the working components.
• Fixed Orifice: The fixed orifice allows the pilot oil a path to return to the tank.
• Pressure Port: This is where pressurized fluid from the pump enters the valve.
• Spool: When pressurized oil opens the pilot, it then pushes the spool to a position to
allow free flow of pressurized oil to the tank.
• Internal Pilot: The internal pilot allows a small amount of pressurized oil through the
valve to the poppet on its seat, when the oil in the pilot has a pressure greater than the
resistance of the pilot spring, it will push the poppet off of its seat and allow pressurized
oil to shift the spool and open the valve.
• Main Spring: The main spring has a factory set resistance allowing the valve to remain
closed until a predetermined pressure range is reached.
• Main Poppet: This is the area that pressurized oil pushes against to shift the spool and
open the valve.
• External Pilot Port: In some applications, this port will be used to open the valve from a
pressure line that is remote from the valve.
• Seat: This is where the poppet rests, creating a metal to metal seal.
• Pilot Poppet: This is the area where high pressure oil pushes against to open the valve.
• External drain: Some applications may use an external drain.
• Jam Nut/ Locking Nut: The inside is threaded, allowing the screw to adjust the spring
tension, therefore changing the cracking pressure of the pilot poppet off the seat.
• Screw: Attaches the adjustment knob to the spring retainer.
• Adjustment Knob: This is what you turn to allow you to adjust the working pressure of
the valve.
• Spring Retainer: Holds the spring in place.
• Pilot Spring: An adjustable spring creating resistance against the poppet, allowing the
valves working pressure to be changed.
• Tank Port: This is where oil leaves the valve, on it’s return journey to the tank.
• Low Pressure Fluid: This is when the fluid has a free path of flow back to the tank, with
minimal resistance.

A pilot operated relief valve is an ingenuous and incredibly useful valve. Without a pilot
operated relief, a hydraulic systems life expectancy will be reduced by years because of
constant pressure spikes without relief. Every hydraulic system designer should always
include a pilot operated relief valve, or else!