Service Training

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.
2.
3.
4.

Components Layout
Operation
Maintenance
Testing & Adjusting

777D Off Highway Truck

CHAPTER : HOIST SYSTEM

777D HOIST SYSTEM

COMPONENT LOCATIONS

ORIFICE PLATE
HOIST PUMP
OIL COOLER
HOIST & BRAKES

SLACK
ADJUSTER

CAB

TRANSMISSION
NEUTRALIZER
SWITCH

HOIST RELIEF
HOIST CONTROL
VALVE
VALVE
OIL COOLING
RELIEF VALVE

HOIST PUMP

HOIST
RELIEF
VALVE

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ORIFICE PLATE
OIL COOLING HOIST
CONTROL
RELIEF
VALVE
VALVE

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
COOLERS

RELIEF VALVE

CYLINDER
ROD END
PORT

CYLINDER
HEAD END
PORT

HOIST VALVE
RAISE
FROM
PUMP

LOAD CHECK VALVE

DETENT

TO BRAKE
COOLERS

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CYLINDER
ROD END
PORT

CYLINDER
HEAD END
PORT

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HOIST SYSTEM
HOLD
LOAD
CHECK VALVE
HOIST
RELIEF
VALVE

HOIST
PUMP

777D Off Highway Truck

TO HOIST & BRAKE

COOLER

CHAPTER : HOIST SYSTEM

BRAKE COOLING
RELIEF VALVE

777D Off Highway Truck

CHAPTER : HOIST SYSTEM

HOIST VALVE
LOWER
RELIEF VALVE
FROM
PUMP

LOAD CHECK

DETENT

NO FLOW
FROM CYLINDERS
HEAD END

TO CYLINDERS
ROD END

RELIEF VALVE

HOIST VALVE
FLOAT
FROM
PUMP

LOAD CHECK

DETENT

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HOIST SYSTEM
RAISE

LOAD
CHECK VALVE
HOIST
RELIEF
VALVE

BRAKE COOLING
RELIEF VALVE

777D Off Highway Truck

CHAPTER : HOIST SYSTEM

TO DIVERTER VALVE &

HOIST/BRAKE COOLER

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
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

CHAPTER : HOIST SYSTEM

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

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

BRAKE COOLING
RELIEF VALVE

TO BRAKE COOLER

RAISE

HOIST
RELIEF
VALVE

HOIST RELIEF
VALVE

LOAD
CHECK VALVE

769D - 777D
HOIST SYSTEM

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

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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.
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

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.
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

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.

____

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.

Head end port of the hoist cylinders

Behind the operators seat in the cab

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