INSTALLATION AND PARTS MANUAL

MT3300, 3700, 4400 & MT6300

ELECTROHYDRAULIC PILOT DUMP
VALVE MODIFICATION

FOR

BUCYRUS MINING

DESIGNED AND BUILT BY

BERENDSEN FLUID POWER
PERTH, AUSTRALIA

BERENDSEN FLUID POWER. UNIT2, 9-11 COLQUHOUN RD, PERTH AIRPORT, W.A. 6105 AUSTRALIA
Issue No: Rev 3
Date: 19/05/09

Job No:
7339055

INDEX

1. GENERAL NOTES

2. INSTALLATION

3. COMMISSIONING / FAULT FINDING

4. RECOMMENDED SPARES

5. REFERENCE DRAWINGS

BERENDSEN FLUID POWER. UNIT2, 9-11 COLQUHOUN RD, PERTH AIRPORT, W.A. 6105 AUSTRALIA
Issue No: Rev 3
Date: 19/05/09

Job No:
7339055

1. GENERAL NOTES

BERENDSEN FLUID POWER. UNIT2, 9-11 COLQUHOUN RD, PERTH AIRPORT, W.A. 6105 AUSTRALIA
Issue No: Rev 3
Date: 19/05/09

Job No:
7339055

1. General notes:
1.1. Ensure all components are present in the kit (both the
modification and installation kit), and that you have read and
understand this manual.
Pilot dump valve modification & installation kit.
Part number: BFPPZ1019

1.2. The pilot valve in that the trucks limit the tray lowering speed via
a pressure relief valve and have a “maintenance lower control”
consisting of a flow control valve and solenoid valve. The
customer must fit these valves (if not fitted).
1.3. All (see note) components of the electrohydraulic valve have
been factory tested and set before shipping, therefore no
further adjustments are required once installed. This is also
true for the electronic controller.
NOTE: The “maintenance lower control” flow control valve
will require setting, the setting procedure is
described in section 3.2.
1.4. Follow all relevant safety procedures before attempting to install
this modification, also ensure that the hydraulic system is de-
pressurised. The dump truck tray should be resting on the
dump truck body or mechanically restrained from falling before
work commences with this modification.
1.5. Before attempting to work on any hydraulic system, all external
components should be thoroughly cleaned. Note the position
of all hoses on the old mechanical valve, as the port location in
the electrohydraulic valve are not in the same location as the
existing mechanical valve.
1.6. Estimate installation time for the dump trucks is 8 hours,
requiring a C9 classified fitter and an automotive electrician.

Photograph 1

BERENDSEN FLUID POWER. UNIT2, 9-11 COLQUHOUN RD, PERTH AIRPORT, W.A. 6105 AUSTRALIA
Issue No: Rev 3
Date: 19/05/09

Job No:
7339055

Joy stick control

Emergency Dump body

stop button override switch

Circuit breaker reset

button “Maintenance control”
push button

Photograph 1 showing the correct assembly of the joy stick and

electrical controller, photograph is typical of both the and
MTXXXX trucks.

BERENDSEN FLUID POWER. UNIT2, 9-11 COLQUHOUN RD, PERTH AIRPORT, W.A. 6105 AUSTRALIA
Issue No: Rev 3
Date: 19/05/09

Job No:
7339055

2. INSTALLATION

BERENDSEN FLUID POWER. UNIT2, 9-11 COLQUHOUN RD, PERTH AIRPORT, W.A. 6105 AUSTRALIA
Issue No: Rev 3
Date: 19/05/09

Job No:
7339055

2. INSTALLATION

2.1. All Trucks

The electrohydraulic pilot dump valve has been

designed as a direct replacement for the old
mechanical pilot dump valve. The port locations
and mounting holes are in the same location as
the old mechanical pilot dump valve.

Refer to drawings PCH00139-A for the hydraulic installation

and PCE00162 for the electrical installation.

Ensure that the 12 core solenoid valve cable has the cover
plate and gland fitted before proceeding. The photograph
below shows what the cover plate and gland looks like.

Photograph 5

Power cable

12 core solenoid valve

cable

J-stick cable (has a

plug on the end)

Photograph of the cover plate, gland and cable.

Before removing the old steel control cable attached the 12

core solenoid valve cable to the end of the cable in the cab, the
steel control cable can now be removed by carefully pulling the
cable through from the valve end.
Before fitting the electrohydraulic pilot dump valve check that
the valves as shown in photograph 6 are fitted if not, remove
the plastic plugs and install the valves in the correct cavity’s
shown in the photograph no the next page. Lubricate the valve
“o” rings with petroleum jelly (or suitable equivalent) before
installing.

BERENDSEN FLUID POWER. UNIT2, 9-11 COLQUHOUN RD, PERTH AIRPORT, W.A. 6105 AUSTRALIA
Issue No: Rev 3
Date: 19/05/09

Job No:
7339055

MTXXXX installation (continued)

Photograph 6

Solenoid valve

Flow control

Relief valve

The MT4400 pilot dump valve must look like the

photo above prior to installation.
The relief valve (part N° RV10-22A-0-N-25
stamped on the valve body) must be fitted to
cavity N°3.
The solenoid valve (part N° SV10-23-0-N-0
stamped on the valve body) must be fitted to
cavity N°1
The flow control valve (part N° NV10-20A-0-N
stamped on the valve body) fitted to cavity N°2
These cavity numbers are stamped into the
manifold next to the cavities.

Before removing the old pilot valve hoses, identify each hose
with a tag. Remove the old pilot dump valve, the new
electrohydraulic pilot dump valve can now be bolted in place
using the SHCS provided. Replace all the “O” rings on the
fitting as provided with the “O” ring’s in the installation kit.

Position the joystick mounting plate over the existing hole in the
cab floor and mark the position of the four mounting holes, drill
and tap M8 holes through. Bolt the joystick and electrical
controller to the mounting plate.

BERENDSEN FLUID POWER. UNIT2, 9-11 COLQUHOUN RD, PERTH AIRPORT, W.A. 6105 AUSTRALIA
Issue No: Rev 3
Date: 19/05/09

Job No:
7339055

Truck installation (continued)

Connect the cannon plug to the socket and pull the solenoid
valve control wires through under the cab. Mount the terminal
strip on the hydraulic cabinet next to the electrohydraulic pilot
dump valve and terminate the solenoid valve control wires to
this terminal strip. The DIN plugs can now be terminated to
their corresponding wire on the terminal strip.

Connect the power cable to a suitable 24 VDC power source

and earth connection. The maximum current draw will be 5
amps.

The installation is now complete.

BERENDSEN FLUID POWER. UNIT2, 9-11 COLQUHOUN RD, PERTH AIRPORT, W.A. 6105 AUSTRALIA
Issue No: Rev 3
Date: 19/05/09

Job No:
7339055

3. COMMISSIONING / FAULT FINDING

BERENDSEN FLUID POWER. UNIT2, 9-11 COLQUHOUN RD, PERTH AIRPORT, W.A. 6105 AUSTRALIA
Issue No: Rev 3
Date: 19/05/09

Job No:
7339055

3 COMMISSIONING / FAULT FINDING

COMMISSIONING

Before starting the engine check the following:

 That all hydraulic connections are tight.

 With the electrical power on, the following LED’s on the
solenoid valve DIN plug should illuminate.
Joystick in the hold position, no LED’s should be on.
Joystick in the float position, LED on solenoid valve
SV-2 must be on.
Joystick in the lower position, LED’s on solenoid
valves SV-1 and SV-3 must be on.
Joystick in the raise position, LED’s on solenoid
valves SV-1 and SV-4 must be on.
With the joystick in hold press and hold the
“maintenance lower control” push button, LED’s on
solenoid valve SV-1, SV-3 and SV-5 must be on.

Place the joystick in the hold position and start the engine,
check that the tray does not move. Operate the joystick and
confirm that the tray moves correctly. If the tray raises with the
joystick in the lower position and lowers with the joystick in the
raise position then the hydraulic “A” and “B” connection are
incorrectly installed. Reverse the “A” and “B” hoses and
recheck the operation. Install a 0-3000psi pressure gauge at
G3, lower the tray until the tray is resting on the body. Keep the
joystick in the lower position, note the pressure on the gauge
which should be 1500psi (±100psi). If the pressure is lower
than 1500psi (±100psi) then the “A” and “B” hoses need to be
reversed as well as the DIN connectors on solenoid valves SV-
3 and SV-4 (check the wiring first). Recheck and confirm the
operation.

While lowering the dump truck tray, activate the emergency

stop button, check that the tray stops moving. The emergency
stop defaults to the hold position.

BERENDSEN FLUID POWER. UNIT2, 9-11 COLQUHOUN RD, PERTH AIRPORT, W.A. 6105 AUSTRALIA
Issue No: Rev 3
Date: 19/05/09

Job No:
7339055

commissioning (continued)

“Maintenance lower control” adjustment.

Note: The joy-stick must be in the hold position for the

maintenance lower control to operate.

Physically locate the flow control valve on the pilot dump valve
body (see photograph 5, Section 2.2 MTXXXX Installation, also
drawing PCH00139-A in section 5) loosen the adjuster lock nut
and fully screw in the adjuster, then back out one turn. Fully
raise the tray, press and hold the “maintenance lower control”
button and check that the tray lowers in a smooth and
controlled fashion. If the tray lowers too fast screw in the flow
control valve adjuster, If the tray lowers too slowly screw out the
flow control valve adjuster. Tighten the adjuster lock nut once
the operation is satisfactory.

Examine all hydraulic connections for leaks, if leaks are found

stop the engine, de-pressurise the hydraulic system and repair
the leak.
Do not attempt to repair any leaks by tightening the fitting
with engine operating or pressure in the hydraulic system.

The dump truck is now ready for operation.

BERENDSEN FLUID POWER. UNIT2, 9-11 COLQUHOUN RD, PERTH AIRPORT, W.A. 6105 AUSTRALIA
Issue No: Rev 3
Date: 19/05/09

Job No:
7339055

FAULT FINDING

The technique of fault finding is normally a process of

elimination. The LED’s on the solenoid valves are a good tool
for fault finding. Obvious faults like blown hydraulic hoses or
loose electrical connections have not been included in the fault
finding chart.

Fault finding chart

FAULT CAUSE SOLUTION

No response from  Emergency stop activated  Reset the emergency stop.

the joystick.
 Circuit breaker tripped.  Reset, if fault persist locate fault (ie:
electrical short) and rectify. If no obvious
fault replace the electrical controller.

 Loss of 24VDC supply.  Check and rectify, if OK and the LED’s do

not operate, fault is in the controller –
replace the electrical controller.

 Faulty joystick control.  Replace the joystick controller.

 Loss of hydraulic pressure.  Check the pressure at test point G1 on the

electrohydraulic pilot dump valve. If no
pressure problem with truck hydraulics, if
pressure check solenoid valve SV-1 for
operation.

LED’s operate, dump  Solenoid valve coil/s failed.  Replace the faulty coil/s.
truck tray does not
operate  Loss of hydraulic pressure  Check the pressure at test point G1 on the
electrohydraulic pilot dump valve. If no
pressure problem with truck hydraulics, if
pressure check solenoid valve SV-1 for
operation.

Dump truck tray does  Faulty solenoid valve.  Replace solenoid valve coil/s SV-1 and or
not lift. SV-4. If fault persists replace the
electrohydraulic pilot dump valve.

 Faulty joystick control.  Replace the joystick controller.

 Fault with the truck hydraulics.  Rectify.

Dump truck tray does  Faulty solenoid valve.  Replace solenoid valve coil/s SV-1 and or
not lower. SV-3. If fault persists replace the
electrohydraulic pilot dump valve.

 Faulty joystick control.  Replace the joystick controller.

 Fault with the truck hydraulics.  Rectify.

Dump truck tray does  Faulty solenoid valve.  Replace solenoid valve coil SV-3. If fault
not float. persists replace the electrohydraulic pilot
dump valve.

BERENDSEN FLUID POWER. UNIT2, 9-11 COLQUHOUN RD, PERTH AIRPORT, W.A. 6105 AUSTRALIA
Issue No: Rev 3
Date: 19/05/09

Job No:
7339055

fault finding (continued)

Fault finding chart (continued)

FAULT CAUSE SOLUTION

Maintenance lower  Joy-stick not in the hold  Place the joy-stick in the hold position.
control does not position.
operate.
 Circuit breaker tripped.  Reset, if fault persist locate fault (ie:
electrical short) and rectify. If no obvious
fault replace the electrical controller.

 Faulty solenoid valve.  Replace solenoid valve coil SV-1 and or

SV-3. If fault persists replace the
electrohydraulic pilot dump valve.

 Faulty “Maintenance lower  Replace the electrical controller.

control switch”.

 Flow control valve not correctly  Adjust the flow control valve as per section
adjusted. 3.2.

Maintenance lower  Flow control valve not correctly  Adjust the flow control valve as per section
control lowers too adjusted. 3.2.
fast.
 Faulty solenoid valve.  Replace solenoid valve coil SV-5. If fault
persists replace the electrohydraulic pilot
dump valve.

BERENDSEN FLUID POWER. UNIT2, 9-11 COLQUHOUN RD, PERTH AIRPORT, W.A. 6105 AUSTRALIA
Issue No: Rev 3
Date: 19/05/09

Job No:
7339055

4. RECOMMENDED SPARES

BERENDSEN FLUID POWER. UNIT2, 9-11 COLQUHOUN RD, PERTH AIRPORT, W.A. 6105 AUSTRALIA
Issue No: Rev 3
Date: 19/05/09

Job No:
7339055

4 RECOMMENDED SPARES

The spares listed below are suitable for the maintenance of one (1)
to five (5) dump trucks.

4.1. MTXXXX
Reference drawing number PCH00139-A / PCH00152-A

Item No Description Qty Part Number

4 Solenoid coil (24VDC) 2 507848

(dwg PCH00139)
8 Cartridge valve coil (24VDC) 2 6356024-DG
(dwg PCH00139)
1 Electrohydraulic pilot dump 1 BFPPZ1019-1
(dwg PCH00139) valve

31 Electrical controller 1 BFPPZ1019-3

(dwg PCH00139)
17 comprising Joy-stick controller assembly 1 BFPPZ1019-2
of items (includes, bracket, e/stop and
the dump body override switch)
18 through to 30
(dwg PCH00139)
Electrohydraulic dump valve 2 PCH00139/SK
seal kit

BERENDSEN FLUID POWER. UNIT2, 9-11 COLQUHOUN RD, PERTH AIRPORT, W.A. 6105 AUSTRALIA
Issue No: Rev 3
Date: 19/05/09

Job No:
7339055

5. REFERENCE DRAWINGS

Drawing Title Drawing Number

Hydraulic Schematic PCH00139-RevB

Electrical Schematic PCE00162-RevB

BERENDSEN FLUID POWER. UNIT2, 9-11 COLQUHOUN RD, PERTH AIRPORT, W.A. 6105 AUSTRALIA