Service Training
MALAGA
777 D Off Highway Truck
VI. HOIST SYSTEM
1. Components Layout
2. Operation
3. Maintenance
4. Testing & Adjusting
777 D Off Highway Truck
CHAPTER : HOIST SYSTEM
Adolfo
August 1997
777 D HOIST SYSTEM
COMPONENT LOCATIONS
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777 D Off Highway Truck
CHAPTER : HOIST SYSTEM
HOIST PUMP
HOIST ORIFICE PLATE
OIL COOLING HOIST
RELIEF RELIEF CONTROL
VALVE VALVE VALVE
TWO STAGE
HOIST CYLINDER
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777 D Off Highway Truck
CHAPTER : HOIST SYSTEM
RAISE
TWO STAGE
HOIST CYLINDER
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777 D Off Highway Truck
CHAPTER : HOIST SYSTEM
LOWER
HOIST VALVE
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777 D Off Highway Truck
CHAPTER : HOIST SYSTEM
ROD END HEAD END
COOLERS PORT PORT
HOIST VALVE PORT
PORT
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777 D Off Highway Truck
CHAPTER : HOIST SYSTEM
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777
D Off: Highway
CHAPTER HOIST Truck
SYSTEM
HOIST SYSTEM
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777 D Off Highway Truck
CHAPTER : HOIST SYSTEM
HOIST VALVE
LOWER
ROD END HEAD END
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777
D Off: Highway
CHAPTER HOIST Truck
SYSTEM
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777 D 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
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777 D Off Highway Truck
CHAPTER : HOIST SYSTEM
LAB EXERCISES
_____ Hoist Lever Switch (Transmission Neutralizer)
_____ Orifice Plate (769D - 777D)
Lab B: Adjust Hoist Lever Linkage
This lab allows you to gain hands on experience checking and adjusting
the hoist control lever linkage adjustment.
BACKGROUND
INFORMATION
The lab also allows you to gain hands on experience checking the
transmission neutralizer switch for correct operation.
Mechanic’s Tool Box and hand tools
MATERIALS NEEDED
Appropriate Service Manual Modules: Hydraulic System Operation,
Testing and Adjusting
Check and adjust the hoist control lever linkage on an Off-highway
GROUP EXERCISE Truck.
After the linkage has been checked and adjusted, check for correct
operation of the transmission neutralizer switch.
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777 D 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
EXERCISE
your answers on the appropriate Lab C Worksheet for Off-highway
Truck
Hoist Test.
769D-777 D OFF-HIGHWAY TRUCK
HOIST TEST
Machine Model__________________________ Date
__________________________________
Customer
Serial # ________________________________
______________________________
Dealer _________________________________ SMH _________________________________
Serviceman _____________________________ Application ____________________________
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CHAPTER : HOIST SYSTEM
LAB EXERCISES
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
LAB D: TRACING HOIST SYSTEM OIL FLOW
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777 D Off Highway Truck
CHAPTER : HOIST SYSTEM
LAB EXERCISES
Directions: Trace the flow of oil in the RAISE position using different colored pencils.
D - 777D
SYSTEM
HOIST
769
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777 D Off Highway Truck
CHAPTER : HOIST SYSTEM
POST TEST
769D-777 D 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
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CHAPTER : HOIST SYSTEM
B. centering spring on the directional spool
C. ball detent on the directional spool
D. small gremlin living in the hydraulic tank
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
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CHAPTER : HOIST SYSTEM
____ 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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