Service Training MALAGA

777D Off Highway Truck

BRAKE COOLING RELIEF VALVE TO HOIST & BRAKE COOLER

HOIST PUMP

VI. HOIST SYSTEM

777D Off Highway Truck

777D HOIST SYSTEM COMPONENT LOCATIONS

ORIFICE PLATE HOIST PUMP OIL COOLER HOIST & BRAKES

CAB

SLACK ADJUSTER

TRANSMISSION NEUTRALIZER SWITCH

HOIST RELIEF HOIST CONTROL VALVE VALVE OIL COOLING RELIEF VALVE

HOIST PUMP

HOIST RELIEF VALVE

ORIFICE PLATE OIL COOLING HOIST CONTROL RELIEF VALVE VALVE

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777D Off Highway Truck

TWO STAGE HOIST CYLINDER RAISE

FIRST STAGE

SECOND STAGE

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777D Off Highway Truck

TWO STAGE HOIST CYLINDER LOWER

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777D Off Highway Truck

HOIST VALVE
RELIEF VALVE

HOLD
FROM PUMP

LOAD CHECK VALVE

DETENT

TO BRAKE COOLERS

CYLINDER ROD END PORT

CYLINDER HEAD END PORT

RELIEF VALVE

HOIST VALVE
RAISE
FROM PUMP LOAD CHECK VALVE

DETENT

TO BRAKE COOLERS

CYLINDER ROD END PORT

CYLINDER HEAD END PORT

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HOIST SYSTEM
HOLD
LOAD CHECK VALVE HOIST RELIEF VALVE

BRAKE COOLING RELIEF VALVE TO HOIST & BRAKE COOLER

CHAPTER : HOIST SYSTEM

777D Off Highway Truck

HOIST PUMP

777D Off Highway Truck

HOIST VALVE
LOWER
RELIEF VALVE FROM PUMP

LOAD CHECK

DETENT

NO FLOW TO CYLINDERS ROD END FROM CYLINDERS HEAD END

RELIEF VALVE

HOIST VALVE
FLOAT
FROM PUMP LOAD CHECK

DETENT

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HOIST SYSTEM
RAISE
HOIST RELIEF VALVE LOAD CHECK VALVE

BRAKE COOLING RELIEF VALVE

CHAPTER : HOIST SYSTEM

TO DIVERTER VALVE & HOIST/BRAKE COOLER

777D Off Highway Truck

777D Off Highway Truck

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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LAB EXERCISES
Lab B: Adjust Hoist Lever Linkage
BACKGROUND INFORMATION

This lab allows you to gain hands on experience checking and adjusting 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

Mechanics 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

LAB EXERCISES
Lab C: Hoist System Diagnostic Testing
BACKGROUND INFORMATION

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

MATERIALS NEEDED

Appropriate Service Manual Module Mechanics 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 EXERCISE

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

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777D Off Highway Truck

LAB EXERCISES
769D-777D OFF-HIGHWAY TRUCK HOIST TEST
Machine Model__________________________ Serial # ________________________________ Dealer _________________________________ Serviceman _____________________________ Date __________________________________ Customer ______________________________ SMH _________________________________ Application ____________________________

VISUAL CHECKS
Oil Level _______________________________ Air/Water in Oil? ________________________ Oil Leaks?______________________________ Oil Viscosity ___________________________ Suction Screen Debris? ___________________ Oil Filter Examination____________________

TEST DRIFT RAISE TIME RELIEF VALVE PRESSURE

SPECS

ACTUAL

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777D Off Highway Truck

LAB EXERCISES
LAB D: TRACING HOIST SYSTEM OIL FLOW Directions: Trace the flow of oil in the RAISE position using different colored pencils.

HOIST RELIEF VALVE

BRAKE COOLING RELIEF VALVE

TO BRAKE COOLER

769D - 777D HOIST SYSTEM

LOAD CHECK VALVE

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777D Off Highway Truck

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. B. C. D. Raise Lower Hold Float

7. The _____ holds the hoist lever in the float position after the operator releases the lever. A. B. C. D. ratchet pawl on the hoist lever centering spring on the directional spool ball detent on the directional spool small gremlin living in the hydraulic tank

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777D Off Highway Truck

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. B. C. D. directional spool orifice plate centering spring 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. B. C. D. directional spool load check valve relief valve 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. B. C. D. Raise Lower Hold Float

Directions: Match the component with the correct location by placing the letter next to the component. ____ ____ ____ ____ ____ ____ ____ ____ ____ Hoist Supply Pump Suction Screen Pilot Operated Relief Valve Hoist Control Valve Brake Cooling Relief Valve Float Position Ball Detent Transmission Neutralizer Switch Orifice Plate Hoist System Pressure Tap A. Inside the hydraulic tank B. Rod end port of the hoist cylinders C. On the hoist valve directional spool D. Below the hoist valve E. On the pump drive near the torque converter F. Head end port of the hoist cylinders

G. Behind the hoist pump suction hose in the tank H. Near the inlet port on the hoist control valve I. Behind the operators seat in the cab

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