BI618554

Bucyrus
All Rights Reserved

BUCYRUS
R

Technical Manual

BI618554

BUCYRUS

DUMP PILOT VALVE

DUMP PILOT VALVE

DESCRIPTION AND LOCATION
The dump pilot valve is a small multi-ported, spool-type
valve mounted in the hydraulic components box behind the left side of the cab.

5. Disconnect all hoses and wiring to the valve. Label

each to and during installation. Install clean plugs or
caps over all openings.
6. Remove the capscrews that secure the valve.

NOTE: The Dump Controller cable linkage must be

removed to remove the pilot valve assembly.

OPERATION
The dump pilot valve has two functions:

7. Remove the valve.

1. It serves as a directional valve, controlling the pilot
flow of pressurized fluid to the main spools in the dump
valve. This flow directs their operation and thus controls the operation of the entire system.
2. It limits the maximum pressure in the Lower or Power
down mode to assist in controlling the rate at which oil
is returned to the hydraulic reservoir.

DISASSEMBLY
NOTE: Note the position and orientation of parts during disassembly. Some parts are not interchangeable.
Some parts that appear symmetrical may not be turned
around.
The pilot valve may be disassembled as follows:

TROUBLESHOOTING
For detailed troubleshooting information, see the chart
in the module on the dump valve in Section 5 - Hydraulic System.

1. Separate the inlet (1), spool (2), and outlet (3) sections of the valve as follows:
a. Loosen and remove the locknuts securing the
sections together.

MAINTENANCE AND ADJUSTMENT

Periodic maintenance should include the following steps:

2. Carefully separate the sections. Inspect all seals

between sections.

1. Inspect all hoses and lines for evidence of damage

or leakage. Repair or replace as required.

NOTE: Do not pry the sections apart with sharp instruments as they may cause damage to mating surfaces.

2. Inspect each assembly component for evidence of

wear, damage, or leakage.

2. Remove screws (12).

3. Test the operation of the valve as outlined in the system operation test in Section 5 -Hydraulic System.

3. Remove the end cover (13), O-ring (30), and wiper

ring (29).

REMOVAL

4. Remove the detent assembly from the other end of

the section.

The dump pilot valve may be removed as follows:

1. Park the truck in a SAFE POSITION. It must be
secured by means other than the friction brake system.
2. Lower the dump body onto the frame. Move the Dump
Controller lever to the Float position.

5. Carefully slide the entire spool assembly out of the

main body with the detent section.
6. Remove the O-ring (30), and wiper ring (29) from the
detent end of the housing.
7. Unscrew the spool from the detent assembly.

3. Shut the engine off.

8. Disassemble the detent assembly as follows:
4. Verify that all pressure has been relieved from the
system.

01/10/96

M1591

BI618554

a. Remove internal retaining ring (23) and spacer

(22).

b. Secure with internal retaining ring (23) and spacer

(22).

b. Remove the internal retainer and balls as required.

4. Install the spool on the detent assembly and tighten

to approximately 5 ft-lbs (7 Nm).

c. Remove all remaining seals and components.

9. Remove the relief valve (4) from the side of the spool
section.

NOTE: It is recommended that a thread locking compound (Loctite 271 or equivalent) be used to prevent
accidental separation of the components during operation. No compound should remain on the outer surface
of the spool when assembled.

INSPECTION AND REPAIR

The pilot valve may be serviced as follows:

6. Install the O-ring (30), and wiper ring (29) on the detent end of the housing.

1. Clean all parts, including the housing, and dry with

compressed air.

7. Carefully slide the entire spool assembly into the main

body with the detent section.

2. Inspect seal counter-bores. They must be free of

nicks and contamination.

8. Install the detent assembly onto the end of the spool

section.

3. Inspect the springs for cracks, distortion, or fatigue.

NOTE: It is recommended that a mild thread locking

compound (Loctite 242 or equivalent) be used to prevent accidental separation of the components during
operation. No compound should remain on the outer
surface of the spool when assembled.

4. Inspect all sliding surfaces for nicks, scores, or excessive wear.

5. Inspect all spools for damage or wear. Test spools
for proper fit in their bores. They should turn free through
one complete revolution.

INSTALLATION
The dump pilot valve may be installed as follows:

6. Examine O-rings for damage or excessive wear.

1. Position the valve on the mounting bracket.

ASSEMBLY
The pilot valve may be assembled as follows:

2. Install capscrews and tighten to secure the valve in

place.

1. Coat all parts, including the housing bores, with hydraulic oil.

3. Install all hydraulic and electrical connections and

secure to the valve.

2. Install the relief valve assembly (4) fitted with new

seals (5) on the side of the spool section.

4. Test the operation of the system as outlined in the

testing procedures under system operation in Section 5
- Hydraulic System.

3. Assemble the detent assembly as follows:

a. Assemble the components as shown in the reverse order removed.

NOTE: Verify that all relief valves are properly set,

particularly the pressure down relief setting controlled
by the pilot valve.

NOTE: It may be desirable to hold the detent balls in

place with grease during the assembly process.

M1591

01/10/96

BI618554

BUCYRUS

DUMP PILOT VALVE

KEY

01.
02.
03.
04.
05.
06.
07.
08.
09.

Inlet Section Assembly

Spool Section Assembly
Outlet Section Assembly
Relief Valve Assembly
Seal and Spring Repair Kit
Shut-off Plug Assembly
Special Seal
Tie Rod
Special Nut

10.
11.
12.
13.
14.
15.
16.
17.
18.

Tie Rod
Special Nut
Machine Screw
Seal Plate
Outlet Housing
O-ring
Spring Seat
Spring
Detent Sleeve

19.
20.
21.
22.
23.
24.
25.
26.
27.

55561

Spool Cap
Ball
Spool End Detent Pin
Spacer
Internal Retaining Ring
Ball
Spring
Spacer
Socket Head Capscrew

28.
29.
30.
31.
32.
33.
34.

Inlet Housing
O-ring
Wiper
Spool
Spool Housing
Check Valve Poppet
Spring

FIGURE 1 - DUMP PILOT VALVE

01/10/96

M1591

BI618554

FIGURE 1 - DUMP PILOT VALVE - CONTINUED

M1591

01/10/96