Service Training

MALAGA

777D Off Highway Truck

HOIST SYSTEM
HOLD

LOAD
CHECK VALVE
HOIST
RELIEF
VALVE

BRAKE COOLING
RELIEF VALVE

TO HOIST & BRAKE

COOLER

HOIST
PUMP

VI. HOIST SYSTEM

1. Components Layout
2. Operation
3. Maintenance
4. Testing & Adjusting
Adolfo
August 1997
 777D Off Highway Truck
CHAPTER : HOIST SYSTEM

777D HOIST SYSTEM

COMPONENT LOCATIONS

ORIFICE PLATE

HOIST PUMP
OIL COOLER
HOIST & BRAKES

SLACK
ADJUSTER
CAB

HOIST RELIEF HOIST CONTROL

TRANSMISSION VALVE VALVE
NEUTRALIZER OIL COOLING
SWITCH RELIEF VALVE

HOIST PUMP

HOIST ORIFICE PLATE

OIL COOLING HOIST
RELIEF RELIEF CONTROL
VALVE VALVE VALVE

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 777D Off Highway Truck
CHAPTER : HOIST SYSTEM

TWO STAGE
HOIST CYLINDER
RAISE

FIRST STAGE

SECOND STAGE

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 777D Off Highway Truck
CHAPTER : HOIST SYSTEM

TWO STAGE
HOIST CYLINDER
LOWER

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 777D Off Highway Truck
CHAPTER : HOIST SYSTEM

HOIST VALVE
RELIEF VALVE
HOLD

FROM
PUMP LOAD CHECK VALVE

DETENT

TO BRAKE CYLINDER CYLINDER

COOLERS ROD END HEAD END
PORT PORT

RELIEF VALVE
HOIST VALVE
RAISE
FROM
PUMP LOAD CHECK VALVE

DETENT

TO BRAKE CYLINDER CYLINDER

COOLERS ROD END HEAD END
PORT PORT

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Page:
VI-5

HOIST SYSTEM
HOLD

LOAD
CHECK VALVE
HOIST
RELIEF
VALVE

BRAKE COOLING
RELIEF VALVE

CHAPTER : HOIST SYSTEM

777D Off Highway Truck
TO HOIST & BRAKE
COOLER

HOIST
PUMP
 777D Off Highway Truck
CHAPTER : HOIST SYSTEM

HOIST VALVE
LOWER

RELIEF VALVE

FROM
PUMP LOAD CHECK

DETENT

NO FLOW

TO CYLINDERS FROM CYLINDERS

ROD END HEAD END

HOIST VALVE
RELIEF VALVE
FLOAT

FROM
PUMP LOAD CHECK

DETENT

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VI-7

HOIST SYSTEM
RAISE LOAD
CHECK VALVE
HOIST
RELIEF
VALVE

BRAKE COOLING
RELIEF VALVE

CHAPTER : HOIST SYSTEM

TO DIVERTER VALVE &
HOIST/BRAKE COOLER

777D Off Highway Truck

 777D Off Highway Truck
CHAPTER : HOIST SYSTEM

LAB EXERCISES
Lab A Worksheet
Hoist System Component Reference Checklist

Directions: Place the correct letter next to the component and give a brief description of each.

Example: _____ Hoist Pump(s)

Supplies oil flow to the hoist system. The 769D - 777D only have one pump.

Hoist System Components

_____ Hoist Pump

_____ Hoist Control Valve

_____ Hoist Relief Valve

_____ Hoist Diverter Valve

_____ Parking Brake Release Valve

_____ Oil Cooling System Relief Valve

_____ Hoist Lever Switch (Transmission Neutralizer)

_____ Orifice Plate (769D - 777D)

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 777D Off Highway Truck
CHAPTER : HOIST SYSTEM

LAB EXERCISES
Lab B: Adjust Hoist Lever Linkage

BACKGROUND This lab allows you to gain hands on experience checking and adjusting
INFORMATION the hoist control lever linkage adjustment.

The lab also allows you to gain hands on experience checking the
transmission neutralizer switch for correct operation.

MATERIALS NEEDED Mechanic’s Tool Box and hand tools

Appropriate Service Manual Modules: Hydraulic System Operation,

Testing and Adjusting

GROUP EXERCISE Check and adjust the hoist control lever linkage on an Off-highway Truck.

After the linkage has been checked and adjusted, check for correct
operation of the transmission neutralizer switch.

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 777D Off Highway Truck
CHAPTER : HOIST SYSTEM

LAB EXERCISES

Lab C: Hoist System Diagnostic Testing

BACKGROUND This lab allows you to gain hands on experience performing pressure
INFORMATION relief, cycle time and drift tests.

MATERIALS NEEDED Appropriate Service Manual Module

Mechanic’s Tool Box and hand tools

1 - 8T0857 Gauge (0-1450 psi)

1 - 8T0859 Gauge (0-3600 psi)
2 - 6V3989 Nipple
2 - 6V4143 Valved Coupler
2 - 6V3079 Diagnostic Hose
2 - 6J3958 1/8-27 NPTF Union
1 - 8T8902 11/16-16 ORFS Tee
1 - Stopwatch
1 - Tape measure
1 - 1U8865 Infrared Thermometer
or
1 - 6V9130 Temperature Adapter Group

INDIVIDUAL OR GROUP Perform relief valve pressure, cycle time and drift tests, and record your
EXERCISE answers on the appropriate Lab C Worksheet for Off-highway Truck
Hoist Test.

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 777D Off Highway Truck
CHAPTER : HOIST SYSTEM

LAB EXERCISES

769D-777D OFF-HIGHWAY TRUCK

HOIST TEST

Machine Model__________________________ Date __________________________________

Serial # ________________________________ Customer ______________________________

Dealer _________________________________ SMH _________________________________

Serviceman _____________________________ Application ____________________________

VISUAL CHECKS

Oil Level _______________________________ Oil Viscosity ___________________________

Air/Water in Oil? ________________________ Suction Screen Debris? ___________________

Oil Leaks?______________________________ Oil Filter Examination____________________

TEST SPECS ACTUAL

DRIFT

RAISE TIME

RELIEF VALVE PRESSURE

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 777D Off Highway Truck
CHAPTER : HOIST SYSTEM

LAB EXERCISES

LAB D: TRACING HOIST SYSTEM OIL FLOW

Directions: Trace the flow of oil in the RAISE position using different colored pencils.

HOIST SYSTEM
769D - 777D
CHECK VALVE
LOAD

BRAKE COOLING
RELIEF VALVE
HOIST RELIEF
VALVE

TO BRAKE COOLER

VALVE
RELIEF
HOIST RAISE

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 777D Off Highway Truck
CHAPTER : HOIST SYSTEM

POST TEST
769D-777D HOIST SYSTEM POSTTEST

Directions: Modified True/False. If a question is false, underline or circle the word or words that make
the statement incorrect and replace with word(s) to make the statement correct.

hoist system
F
Example: _____ 1. This is an engine class.

____ 1. Whenever work is performed under the body while the body is raised, you must install
the safety pins AND disconnect the hoist control linkage.

____ 2. Incorrect adjustment of the hoist control linkage can prevent the transmission from
shifting into reverse.

____ 3. Screens located on top of the hydraulic tank prevent contamination from entering the
hoist system.

____ 4. The hoist system pilot operated relief valve controls the maximum pressure in the brake
cooling system.

____ 5. An orifice plate at the rod end of the hoist cylinders prevents the body from raising
faster than the pump can supply oil to the cylinders (caused by a sudden shift of the
load).

Directions: Multiple Choice. Circle the correct letter(s) of the best answer(s) for each question.

6. Supply oil from the hoist pump flows to the brake cooling system when the hoist lever is in the
_____ position.

A. Raise
B. Lower
C. Hold
D. Float

7. The _____ holds the hoist lever in the float position after the operator releases the lever.

A. ratchet pawl on the hoist lever

B. centering spring on the directional spool
C. ball detent on the directional spool
D. small gremlin living in the hydraulic tank

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 777D Off Highway Truck
CHAPTER : HOIST SYSTEM

POST TEST
8. When the hoist valve is in the hold position with the body raised above the frame, the _____
will prevent the body from lowering.

A. directional spool
B. orifice plate
C. centering spring
D. load check valve

9. If the hoist valve is moved from the hold to the raise position with the body raised above the
frame, the _____ will prevent the body from lowering until pump supply pressure is higher than
the pressure in the head end of the hoist cylinders.

A. directional spool
B. load check valve
C. relief valve
D. orifice plate

10.When the hoist lever is in the _____ position, a small amount of oil pressure in the rod end of
the hoist cylinders holds the body firmly down on the frame to prevent the body from bouncing
when traveling without a load in the body.

A. Raise
B. Lower
C. Hold
D. Float

Directions: Match the component with the correct location by placing the letter next to the component.

____ Hoist Supply Pump A. Inside the hydraulic tank

____ Suction Screen B. Rod end port of the hoist cylinders

____ Pilot Operated Relief Valve C. On the hoist valve directional spool

____ Hoist Control Valve D. Below the hoist valve

____ Brake Cooling Relief Valve E. On the pump drive near the torque converter

____ Float Position Ball Detent F. Head end port of the hoist cylinders

____ Transmission Neutralizer Switch G. Behind the hoist pump suction hose in the tank

____ Orifice Plate H. Near the inlet port on the hoist control valve

____ Hoist System Pressure Tap I. Behind the operator’s seat in the cab

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