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Product:EXCAVATOR
Model:235BEXCAVATOR9PC
Configuration:235BEXCAVATOR9PC00001UP(MACHINE)POWEREDBY
3306ENGINE

SystemsOperation
SUPPLEMENTFOR235BEXCAVATOR
MediaNumberSENR327800

SystemsOperation

Introduction

PublicationDate01/01/1986

DateUpdated11/10/2001


Themajorchangewiththe235Bistheincreaseinnetenginehorsepowerfrom195to215hp.Mostofthehydraulicchangesarearesultofthe
increaseinhorsepower.
Thissupplementmanualcoversthenewcomponentsinthehydraulicsystemforthe235B,someofwhichcomewiththeadditionoftheincreasedlift
systemasnotedinthechartbelow.
Aspartoftheincreasedliftsystemonly,aselectorvalve(4)isusedtodirectandcontrolsignalpressureforincreasedlift,forspeedanddirection,and
forthepumpservos.Aspartoftheincreasedliftsystemonly,stickcheckandventvalvesareprovided,alongwiththeboomcheckandventvalves,to
maintainexactcontrolbyreducingdrift.
Thesummingvalve(14)isalsonowadjustablesothatimplementpressuresurgescanbepreventedfromdisruptingmachineperformance.

IncreasedLift

RIGHTHANDCONSOLE
1.Switch.

Theincreasedliftsystemincreasesimplementworkingpressureforincreasedliftwhilereducingpumpflowforoptimumcontrolofboomandstick.
Increasedliftisenergizedbymovingswitch(1)(locatedontherighthandconsole)totheONposition.Thisenergizesasolenoidinselectorvalve(4)
whichallowsasignaltotheservocontrolvalveforpumps(13).Thisinturndestrokespumps(13).Atthesametime,valve(4)allowsasignaltothe
mainreliefvalve(12).Thisincreasesthemainreliefsettingfrom27600kPa(4000psi)to31000kPa(4500psi).


SELECTORVALVE(LocatedonLeftSideofHydraulicTank)
4.Selectorvalve.5.Trackbrakevalve.12.Mainreliefvalve.

SelectorControlValve(OnlyWithIncreasedLift)
Selectorcontrolvalve(4)isastandardcomponenton235BExcavatorswiththebackhoeattachment.Dependingonmachineoperationand/or
implementloads,valve(4)doesthefollowing:
1.Basedonapilotsignalfromcontrolvalve(2)forspeedanddirection,directssignalpressuretoincreasethesettingofthemainreliefvalve(12)
from276001030kPa(4000150psi)to310001030kPa(4500150psi)forspeedanddirectioncontrol.Atthesametimeitdirectspilotoilto
thetrackbrakevalve(5)toreleasethetrackbrakes.
2.Directssignalpressuretoincreasethesettingofthemainreliefvalve(asabove)whiledecreasingpumpflowduringincreasedlift.
3.Controlsthepressuresignalfromtheunderspeedvalve(7)andsummingvalve(14)totheservosofpumps(13).

SelectorControlValveForwardTravelSignal


SPEEDANDDIRECTIONCONTROLVALVE
2.Controlvalve(speedanddirection).

SELECTORANDTRACKBRAKEVALVES
4.Selectorvalve.5.Trackbrakevalve.15.Outletport(signaloiltomainreliefvalve).20.Outletport(pilotoiltosummingvalve).23.Inlet(pilotoil).26.Inlet(FORWARDtravel
signal).32.Inlet(REVERSEtravelsignal).33.Linetotrackbrake.34.Linefromport(19)tovalve(5).35.Pilotoiltopilotcontrolvalves.36.Oilreturntotank(frompilot
valves).

Signaloilfromspeedanddirectioncontrolvalve(2)entersvalve(4)atinlet(26)andshiftsspool(29)totheleft.Pilotoilentersvalve(4)atinlet(23).
Withspool(29)positionedleft,pilotoilpressurethroughpassages(21)and(24)andchamber(27)isallowedinpassage(25)ofspool(29)and
chamber(30)topassage(18)ofthevalve.Thisallowspressureoilthroughoutletport(19)andline(34)andontovalve(5)forthetrackbrake.Pilot
oilexitsvalve(5)throughline(33)toreleasethetrackbrake.Atthesametimetheparkingbrakeisbeingreleased,pilotoilpressuremovesvalveball
(16)toallowpilotoilatoutletport(15).Thisincreasesmainreliefvalve(12)settingfrom276001030kPa(4000150psi)to310001030kPa
(4500150psi).
Pilotoilfromchamber(27)isalsoinpassage(31)andatlocation(28).[Passage(17)wouldappearinoppositeviewofsectionAA.]Pilotoil
pressureinpassage(17)leavesoutletport(20)asasupplyofpilotoilforsummingvalve(14).

SelectorControlValveReverseTravelSignal(notshown)
Signaloilfromspeedanddirectioncontrolvalve(2)entersvalve(4)atinlet(32)andshiftsspool(29)totheright.Pilotoilpressurefromchamber
(27)isthenallowedpastspool(29)intochamber(30)andpassage(18).Fromthispoint,pilotoilpressureworksthesameasfortheFORWARD
travelsignal.

SelectorControlValveIncreasedLiftSignal

RIGHTHANDCONSOLE
1.Switch.

Inheavyliftapplicationswhereanincreaseinliftingforceisneeded,switch(1)ontherighthandconsoleismovedtotheONposition.Thisenergizes
solenoidvalve(41)whichinturnallowssignaloilpressuretotheservosofpumps(13)andtomainreliefvalve(12).

SELECTORANDTRACKBRAKEVALVES
4.Selectorvalve.5.Trackbrakevalve.12.Mainreliefvalve.15.Outletport(signaloiltomainreliefvalve).20.Outletport(pilotoiltosummingvalve).23.Inlet(pilotoil).38.
Outletport(signaloiltoservosofpumps).41.Solenoidvalve.

Pilotoilentersvalve(4)atinlet(23)andflowsthroughpassages(21)and(24)tochamber(27).Fromchamber(27),pilotoilflowsthroughpassage
(31)tolocation(28)[passage(17)wouldappearinoppositeviewofsectionAA].Pilotoilpressureinpassage(17)leavesoutletport(20)asasupply
ofpilotoilforsummingvalve(14).
Whensolenoidvalve(41)isenergized,thevalvespoolretracts(movestotheright).Pilotoilfromchamber(27)andpassage(31)thenflowsthrough
chamber(42)andpassage(39)tochamber(40)ofvalve(41).Pressureoilisallowedthroughchamber(40)topassage(44),whichmovesvalveball
(43).Thisallowspressureoilatport(38)totheservosofpumps(13).Thisinturnreducespumpoutputflowformoreprecisecontrolofthe
implements.Also,withsolenoidvalve(41)energized,pilotpressureisallowedfromchamber(40)throughapassageatlocation(37).(Thepassage
wouldappearinanoppositeviewofsectionCC.)Pressureoilthenmovesvalveball(16)toallowpressureatport(15)tomainreliefvalve(12).The
reliefsettingisincreasedto31000kPa(4500psi)from27600kPa(4000psi).
Theendresultoftheaboveoperationisthatthestick,boomandbucketmovementwillbeslowerformorecontrol,buttherewillbeincreasedlifting
forceavailable.

HYDRAULICPUMPS
13.Frontandrearpumps.

SelectorControlValveSummingorUnderspeedSignal


Selectorcontrolvalve(4)receivesasignalfromsummingvalve(14)inthecaseofasuddenpressureincreaseorasignalfromunderspeedvalve(7)
whentheenginespeedhasloweredtoapproximately1940rpm.Valve(4)directseitherofthesesignalstotheservosofpumps(13)forreducedpump
flow.
Valve(4)alsoservesthepurposeofdirectingpilotpressureoiltothesummingvalve(14)foruseasasignaloil.

Operation

SELECTORVALVE
4.Selectorvalve.14.Summingvalve.20.Outletport(pilotoiltosummingvalve).23.Inlet(pilotoil).38.Outletport(signaloiltoservosofpumps).45.Pilotreliefvalve.46.Inlet
port(underspeedsignal).47.Inletport(summingsignal).48.Line(signal).49.Line(signal).

Pilotoilpressureenterspassage(21)throughinletport(23)oftheselectorvalve.Theoilpressureisinpassage(24),chamber(27)andpassage(31).
Thepressureoilenterspassage(17)fromapassageatlocation(28)(wouldappearinoppositeviewofsectionAA).Pilotoilexitsport(20)toprovide
pilotoiltosummingvalve(14).
Signaloilfromsummingvalve(14)throughline(48)entersatinlet(47)orunderspeedsignaloilthroughline(49)entersatinlet(46).Thesignaloil
movesvalveball(43)toblockpassage(44)andallowthepressuresignaloiltooutlet(38).Thisoilthenoperatesthepumpservostodestrokethe
frontandrearpumps.
Orificecheckvalve(10)locatedbetweensummingsignalline(48)andselectorcontrolvalve(4)isusedtopreventtheunderspeedsignaloilfrom
enteringline(48)tothesummingvalve.

SUMMINGVALVE

14.Summingvalve.48.Line(signal).

UNDERSPEEDVALVE
7.Underspeedvalve.49.Line(signal).

PilotReliefValve
Thepilotreliefvalve(45)ismountedonselectorcontrolvalve(4).Whenpilotoilpressurereaches2300kPa(335psi),pressureoilisventedthrough
outletpassage(22)totank.Exceptformountinglocation,thisvalvehasnotchangedfromearliermachines.Sincetheflowofoilinthepilotsystemis
sosmall,mostoftheoutputfromthepilotpumpgoesthroughvalve(45).

StickOperation(IncreasedLiftSystem)


STICKHYDRAULICSCHEMATIC
1.Stickcylinder.
2.Oillinefrommaincontrolvalve(7)(forstickIN)toheadendofstickcylinder(1).

3.Oillinetostickcheckandreliefvalve(4)fromrodendofstickcylinder(1).
4.Stickcheckandreliefvalve.
5.Oillinefromvalve(4)tomaincontrolvalve(7).
6.Oilventlinefromvalve(4)toventvalve(11).
7.Maincontrolvalve(stickcontrolvalvesection).
8.Pilotpressureoil(stickIN).
9.Spool.
10.Pilotpressureoil(stickOUT).
11.Ventvalve.
12.Pilotpressureoil.

Togivemoreexactcontrolduringliftingofheavyloads,thestickmustremaininastationaryposition[exceptwhenchangedbyactivationofstick
controlvalve(7)].Thisisaccomplishedbytheuseofstickcheckvalve(4)andventvalve(11)installedinthelinetotherodendofstickcylinder(1).
Checkvalve(4)willkeeptheINdriftofthestickassemblyasnearzeroaspossible.

STICKCONTROLLEVER

StickCheckandReliefValve

NOTE:Foroperationofboomcheckandreliefvalve,seeBOOMLOWERCONTROLinFormNumberSENR7901.

CHECKANDRELIEFVALVE(LeftSideofMachineinMainValveCompartment)
4.Valve.

DuringstickOUT,pumpoilflowsthroughline(5)intopassage(16).Thisoilopenscheckvalve(18)andgoesoutpassage(13).Frompassage(13)
pumpoilflowsthroughline(3)totherodendofstickcylinder(1).
Whenspool(9)incontrolvalve(7)ismovedtoNEUTRAL,valve(18)closes.Theweightoftheloadand/orstickassemblycausespressureinline
(3),passage(13)andthechambeofspring(20).Oilpressure(duetotheload)andtheforceofspring(20)holdvalve(18)closed.Ifanexternalforce
onthestickassemblycausesasuddenincreaseofpressure[approximately38000kPa(5500psi)],reliefvalve(15)opensandoilgoesoutpassage
(14)throughareturnlinetothetank.ThelinereliefvalveforstickINisintheendofvalve(7).Valve(15)instickcheckandreliefvalve(4)isthe
linereliefvalveforstickOUT.
DuringstickIN,oilflowofthemainsystemputspressureontheoilintheheadendofthestickcylinderthroughline(2).Returnoilfromtherodend
ofthestickcylindergoesthroughline(3)topassage(13).Whenspool(9)ismovedtothestickINposition,ventvalve(11)opensawayforreleaseof
oilpressureinthechamberofspring(20).Oilpressureonshoulder(19)ofvalve(18)movesvalve(18)againsttheforceofspring(20).Theoilin
passage(13)goesoutpassage(16)tomaincontrolvalve(7)throughline(5).


CROSSSECTIONOFCHECKANDRELIEFVALVE

4.CheckandreliefvalveforstickIN.13.Oilpassage.14.Oilpassage.15.Reliefvalve.16.Oilpassage.17.Ventvalvesignalpassage.18.Checkvalve.19.Shoulder.20.Spring.

StickVentValve

CROSSSECTIONOFVENTVALVE
11.Ventvalve.21.Spring.22.Plunger.23.Ball.24.Plug.25.Passage.26.Passage.27.Spool.28.Passage.

STICKVENTVALVE

4.Valve(stickcheckandrelief).11.Valve.29.Valve(boomvent).30.Valve(boomcheckandrelief).

WhenthepilotcontrolvalveisintheNEUTRALposition,thereisnooilpressureinpilotoillines(8)and(12).Spring(21)pushesspool(27)tothe
endofthevalvebore.Anyexternalforcethatpushesdownonthestickassemblyputspressureontheoilinline(3)fromtherodendofthestick
cylinderandpassage(13).Checkvalve(18)isheldinplacebytheoilinthechamberofspring(20)andtheoilinline(6).Ball(23)andspool(27)in
ventvalve(11)preventsthisoilfromventing.WhenthepilotcontrolvalveleverispushedtowardstickINposition,thereisapressureincreasein
pilotoillines(8)and(12).Oilpressureinline(12)topassage(28)movesspool(27)againsttheforceofspring(21).Spoolmovementopensaway
foroilflowfrompassage(25),throughthechamberforspring(21),throughpassage(26),toareturnlinetotank.Passage(25)alsocausesareleaseof
oilpressureinthechamberforspring(20)incheckvalve(4).Checkvalve(18)opensforflowofreturnoilfromtherodendofcylinder(1)tovalve
(7)andtoareturnlinetotank.
Inthestickcircuit,plunger(22)andball(23)havenouse(seeBOOMLOWERCONTROL,FormNo.SENR7735forapplication).Plug(24)isused
tosealofftheunusedpassage.
NOTE:Insituationswhereexcessdriftoccurs,makesureplunger(22)isinfarenoughtoseatball(23).

SummingValve
Thesummingvalveworkswiththeunderspeedvalvetocontrolpumpoutput.Theunderspeedvalvecontrolspumpoutputbasedonenginespeedonly
whilethesummingvalvecontrolspumpoutputbasedonlyonpumppressuresurges(suddenpressureincreases).
Inlets(7)and(10)areconnecteddirectlytothechambersinthecombinervalve.Inlet(7)isconnectedtothechamberfortherearpumpandinlet(10)
isconnectedtothechamberforthefrontpump.Throughtheseconnections,anypressureincreaseinthechambersofthecombinervalveresultina
pressureincreaseatinlets(7)and(10).Thepressuresarefeltbyloadpistons(5)and(14).Eachofthefourpistonsmovesindependently(separately
fromeachother).

SUMMINGVALVE(RightSideofMachineNexttoHydraulicTankViewedfromBottomofMachine)

SUMMINGVALVE
1.Outlettotank.2.Spring.3.Orifice(variable).4.Inletforpilotpressureoil.5.Loadpistons(twoforrearpump).6.Cap.7.Inletforcombinervalve.8.Slug.9.Adjustmentscrew.
10.Inletfromcombinervalve.11.Spool.12.Outletforpumpsignalpressure.13.Passagetotank.14.Loadpistons(twoforfrontpump).

Thefourpistons(5)and(14)transmitpumppressuretospool(11).Inaddition,pilotpressurefrominlet(4)actsonthesurfaceareaofslug(8).These
forcesarebalancedagainstthecombinedforceofsignalpressureoilfromoutlet(12)actingagainstthesurfaceareaofspool(11)andtheforceof
spring(2)actingonspool(11).
Whenthecombinationofpressure(summing)[actingonpistons(5)andpistons(14)]gohighenoughtocausespool(11)tomove,variableorifice(3)
openstoallowsignaloiltooutlet(12).
Outlet(12)isconnectedthroughalineandorificecheckvalvetotheunderspeedvalveandpumpservovalves.[Whenincreasedliftispartofthe
hydraulicsystem,outlet(12)isconnectedthroughalineandorificecheckvalvetotheselectorvalvealongwiththeunderspeedsignal.Dependingon

thelargerofthesignals,(summingorunderspeed),thatsignalgoestothepumpservos.]Whenthesummingpressurebecomeshigherthanthesignal
pressurefromtheunderspeedvalve,thesignalfromthesummingvalvecausesthepumpstodecreasetheiroutput.Normallythesignalfromthe
summingvalvetothepumpsisofshortdurationandhappensonlywhenthereisapressuresurge.
Tomakeachangeofthesummingsignalpressuretothepumps,useadjustmentscrew(9).SeeADJUSTINGOFSUMMINGVALVEintheTesting
andAdjustingSection.

PilotControlValves
Oilflowfromthepilotpump,atapressureof2300170kPa(33525psi),isusedtocontrolthemovementofthespoolsinthemaincontrolvalves
forboom,bucket,stickandswing.
Togivetheoperatortheabilitytocontrolthisflowandpressure,twopilotcontrolvalvesareinstalledinthepilotsystem.Oneofthesevalvesisinthe
leftarmrestandcontrolsthestickinandoutmovementandtherightorleftmovementoftheswingcircuit.Theotherpilotvalveisinstalledinthe
rightarmrestandcontrolstheraiseandlowermovementoftheboomandtheopenandclosemovementofthebucket.

PILOTCONTROLVALVE
1.Actuatorplate.2.Plungers(fourineachvalve).3.Retainer.4.Markusedfordisassemblyandassembly.


BOTTOMOFPILOTCONTROLVALVE
5.OutletforboomRAISEorstickOUT.6.OutletforswingLEFTorbucketOPEN.7.OutletstickINorboomLOWER.8.Inletforpilotpressureandflow.9.Outletforreturnpilot
pressureandflow.10.OutletforswingRIGHTorbucketCLOSE.

Thepilotvalvesaremanuallyoperatedandsendpilotoiltotheendofthespoolinthemaincontrolvalveselectedforoperation.
Therearefourpressurereducingtypevalveassembliesineachpilotvalve.Twovalveassembliesareneededtooperateeachofthefourimplements.
Whenacontrolleverismoved,aplungerispusheddowninthepilotvalve.Movementoftheplungercausesavalvestemtomovedownandopena
passageforpilotoiltogotooneendofamaincontrolvalvespool.Thepressureoilattheendofthemaincontrolvalvespoolmovesituntilapassage
isopenedformainsupplyoiltotheimplement,cylinderormotor.
Thetwopilotvalvesarethesame.Threeofthefourvalveassembliesineachvalvearethesame.Thefourthvalve,whichisusedforstickINand
boomLOWER,usesadifferentplunger.Identificationoftheportsisstampedonthebottomofthevalve.

BoomOperationHOLD
WhenthecontrolleversareinHOLDposition,alloftheplungersareinthesameposition.Pilotoilfromthepilotpumpgoesintothevalvethrough
inlet(8)tochamber(25)andisstoppedbythepositionofstems(14)and(15).Passages(23)and(24)areopentotankthroughchamber(22)and
outlet(9).
Spring(20)pushesuponretainer(16)andplunger(2).Spring(18)holdsstem(14)downagainstretainer(16).Spring(19)pushesuponretainer(13)
andplunger(12).Spring(21)holdsstem(15)downagainstretainer(17).Therearespacersbetweentheretainersandplungersthatareusedtochange
theforceofsprings(18)and(19).


PILOTCONTROLVALVE

1.Actuatorplate.2.Plungers(valve1,3&4).3.Retainer.5.Outlet.7.Outlet.11.Retainer.12.Plunger(valve2).13.Retainer.14.Stem.15.Stem.16.Retainer.17.Retainer.18.
Spring(inner).19.Spring(inner).20.Spring(outer).21.Spring(outer).22.Chamber.23.Passage.24.Passage.25.Chamber.

BOTTOMOFPILOTCONTROLVALVE
5.OutletforboomRAISEorstickOUT.6.OutletforswingLEFTorbucketOPEN(shovelDUMP).7.OutletforboomLOWERorstickIN.8.Inletforpilotpressureandflow.9.
Outletforreturnpilotflow.10.OutletforswingRIGHTorbucketCLOSE.26.Passageforelectricalwires.

BoomRaise
WhenthecontrolleverismovedtotheboomRAISEposition,actuatorplate(1)tiltstotheright.Actuatorplate(1)pushesdownonplunger(2)

againsttheforceofspring(20).BoomRAISEstem(14)movesdownwithplunger(2).Theoilfrompumpinlet(8)nowcangothroughpassage(24)
fromchamber(25)andoutpassage(5)totheraiseendofthemaincontrolvalveforboom.Thepressureofthisoilontheendoftheboomvalvespool
causesittomoveintotheRAISEposition.
Theoilfromthechamberattheoppositeendofthemaincontrolvalvespoolforboomcomesbackthroughoutlet(7),throughpassage(23)instem
(15)andthenintochamber(22)andbacktotank.
Oilpressureinoutlet(5)pushesupagainststem(14)andspring(18).Anyincreaseinpressureinoutlet(5)willpushharderagainststem(14)and
spring(18).Asstem(14)movesup,passage(24)isclosedandtheflowofoilisstoppedtooutlet(5)[thepressureremainsinoutlet(5)].Atthispoint,
stem(14)hasmovedoffretainer(16)andisbeingheldinapressuremodulatingposition.Thestemhasestablishedabalancebetweenthepressurein
outlet(5)andtheforceofspring(18).
Whenthecontrolleverhasmovedapproximately85%ofthedistanceforfullboomRAISE,plunger(2)makesdirectcontactwiththetopofstem
(14).Whenthishappens,stem(14)ispusheddownuntilpassage(24)isagainopentopilotpressure.Fullpilotpressurenowgoestooutlet(5).
Whentheboomcontrolleverisreleased,spring(20)pushesuponplunger(2).Actuatorplate(1)returnsthelevertoHOLDposition.Stem(14)
movesupbecauseretainer(16)hasmovedupwithplunger(2)andtheforceofspring(18)isless.Theoilinoutlet(5)canflowthroughpassage(24)
andchamber(22)totank.

BoomLower
TheboomLOWERstem(15)operatesinasimilarmannertotheboomRAISEstem(14).Thedifferenceisinplunger(12)thatwillnevermakedirect
contactwithstem(15).Asaresult,fullpilotpressureof2300kPa(335psi)willneverbesuppliedtooutlet(7).

StickIn
Sincethepilotvalvesareidentical,theoperationofstem(15)willbethesameasboomLOWER.

StickOut,BucketOpenandCloseandSwingRightorLeft
OperationofthepilotvalveforthesefunctionsisthesameasthatdescribedforboomRAISE.


PILOTCONTROLVALVE(StickandSwing)
27.Pilotcontrolvalveforstickandswing.28.Outletlinetotank.29.PilotoillineforstickIN.30.PilotoillineforswingRIGHT.31.Oillinetopilotoilinlet.32.Pilotoillinefor
stickOUT.33.PilotoillineforswingLEFT.

PILOTCONTROLVALVE(BoomandBucket)
34.Pilotcontrolvalveforboomandbucket.35.PilotoillineforboomRAISE.36.Inletforpilotoil.37.PilotoillineforbucketOPEN(shovelDUMP).38.Pilotoillineforboom
LOWER.39.PilotoillineforbucketCLOSE(shovelTILTBACK).
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