EH1600 HOIST SYSTEM

Manual float
down valve

The hoist system consist of the following components:- 1. Hyd tank 2. Hoist pump 3. Pilot control valve 4. Motion control valve
5. Hoist cylinders 6. Filter assembly 7. Cooler assembly 8. Wet disc brake assembly 9. Manual float down valve
The Electronic Hoist Control system consists of electrical, electronic, and
hydraulic components. This is a list of the components that make the
system operate and what is described in this training session.

1. HYDRAULIC TANK
2. STRAINER
3. RELIEF VALVE ASSEMBLY BRAKE
COOLING
4. HYDRAULIC PUMP
5. HYDRAULIC CONTROL VALVE
6. MANUAL FLOAT DOWN VALVE
7. MOTION CONTROL VALVE
7a. CARTRIDGE COUNTER BALANCE
VALVE
8. HOIST CYLINDER RIGHT
9. HOIST CYLINDER LEFT
10. COOLING FILTERS
 HYDRAULIC TANK

CAPACITY
318 LITERS
CAPACITY
117 LITERS
STRAINERS MOUNTED INSIDE TANK
BEHIND COVER PLATES
A. Cavity
HYDRAULIC PUMP
B. Passage
C. Cavity
d. Passage
D. Cavity
E. Passage
F. Cavity
G. Passage
J. Passage

1. Front Drive Gear

2. Seal
3. Snap Ring
4. Front Idler Gear
5. Ball
6. 0- Ring
7. Flange
8. Dowel Pin
9. Front Body
10. Pressure Plate
11. O-Ring
12. Back-up Ring 13. 0- Ring
14. Center Housing 15. 0- Ring
16. Pressure Plate 17. Body
18. Ball
19. 0- Ring
20. Back-up Ring
21. Idler Gear Ring
22. Rear Drive Gear
23. Nut
24. Washer
25. Snap Ring
26. Spline Coupling
27. Plug
28. Rear Idler Gear
 HYDRAULIC PUMP MOUNTING

BRAKE COOLING HOIST

 HOIST/BRAKE COOLING PUMP SUPPLY LINES

BRAKE COOLING HOIST SUPPLY

SUPPLY LINE LINE
 PILOT HYDRAULIC CONTROL VALVE

TO COOLING
FILTER
RETURN
TO TANK

TO HOIST
SUPPLY TO CYLINDERS
MOTION
CONTROL
PUMP
VALVE
SUPPLY
TO MANUAL
FLOAT
DOWN
VALVE

PULSE WIDTH RELIEF VALVE

MODULATED SET TO 2950 psi
PILOT VALVES
 PULSE WIDTH MODULATING VALVE (PWM)

There are two PWM valves mounted on either end

of the hoist control valve to control the
pilot pressure being supplied from the
pressure reducing valve. When the PWM valve
receives a pulsed voltage signal from the
microprocessor, a modulated amount of pilot
pressure (dependent upon the lever position
and the pulsed voltage signal) is directed
against the end of the valve spool to shift
the spool into the position desired by the
operator (RAISE,
HOLD, FLOAT, OR POWER DOWN).
MOTION CONTROL VALVE

COUNTER
BALANCE
VALVE
SET TO 3000 psi

TEST PORT
The motion control valve operates when the hydraulic control valve is
in the RAISE position. The motion control valve restricts hydraulic oil
flow from the rod end of the hoist cylinders. This is accomplished by
the counter balance valve which is constantly being adjusted by
hydraulic pressure sensed at rod end cylinder port C and at pilot port
A. Refer to the schematic in Figure 1. While the dump body is lowering,
hydraulic oil flow through the valve is virtually unrestricted.
Raise (Normal), Figure 2

Hoist cylinder base end pressure is high when the hydraulic control
valve is in the RAISE position. This pressure is applied through the
pilot line to pilot port (A). This pressure acts on the return spring
and unseats the relief poppet. This allows hydraulic oil to return from
the hoist cylinder rod end at low back pressure in port (C) through the
valve and out port (B) to the hydraulic control valve.
Load Shift, Figure 3

As the load slides off the tail chute, it causes the body to raise
faster than the hydraulic system can function. As this occurs, the base
end pressure and pilot pressure begin to drop. When the pilot pressure
can no longer overcome the pressure of the return spring, the relief
poppet begins to reset and restrict the return flow from the rod end of
the hoist cylinder. This restriction creates a high back pressure which
in turn works to slow down the extension of the cylinders.
Lower, Figure 4

When the hydraulic control valve is placed in the LOWER position,

hydraulic oil enters the motion control valve at port (B), passes
through the one-way check valve and exits at port (C). Hydraulic oil
flow is unrestricted to the rod end of the cylinders.
1. Tube Base and Assembly
2. Snap Ring
3. Plug
4. Slotted Wear Ring
5. Inner Seal Ring
6. Outer Seal Ring
7. O-Ring
8. Check Ball
9. Socket Head Screw
10. Washer
11. Adhesive
12. Intermediate Tube Assembly
13. Gland Cap
14. Cap Bolts
15. Washer
16. Piston Rod Assembly
17. U-Cup Rod Seal
18. Wiper Seal
19. Buffer Ring Assembly
20. O-Ring
21. Back-Up Ring
22. Ring
23. Piston
24. Bearing, Rod
25. U-Cup Rod Seal
26. Wiper Rod
27. Buffer Ring
28. Dowel Pin
29. Wear Ring
30. Spherical Bushing
31. Split Flange
32. Bolt
33. Lock Washer
34. Ring
35. Plug, Flange
36. Split Flange
37. O-Ring
38. Flange
39. Ring
40. Plug
41. O-Ring
42. Pin
43. Spool
44. Disc
Port A. (Raised) Port B. (Return)
 COOLING FILTERS

PRESSURE
DIFFERENTIAL
SWITCH SET TO
OPEN AT 35 psi
BYPASS VALVES
SET TO OPEN AT
50 psi
 Filter Restriction Logic:

Engine running + filter lamp on + “E Clean Steer filter” = One of 2 things:

1. open circuit or 2. dirty filter element.

Therefore; determine which it is:

1. 24v + 5 seconds + filter light flashing + “E Steer filter ER” = open circuit.
2. 24v + 5 seconds + no filter light + no warning message = dirty filter.
HOIST/BRAKE COOLER
MANUAL FLOAT DOWN
VALVE
 "RAISE" POSITION
When the body is to be raised off of the frame rail the
hydraulic control valve lever is moved to the furthest upward
position, the RAISE" position. With the hoist control lever
in the "RAISE" position the hoist lever rheostat sends a 3-4
volt signal to the hoist controller. The hoist controller
interprets the voltage as the "RAISE" position then directs a
pulsed voltage signal to the pulse width modulating (PWM)
valve of the hoist control valve. The "RAISE" PWM valve
shuttles to allow the hydraulic pilot pressure 1725-2070 kPa
(250-300 psi) to the end of the hoist control valve spool.
The valve spool shifts into the "RAISE" position allowing the
hoist system hydraulic pressure to flow to the base end of
the hoist cylinders, extending them upwards to dump the load.
With all supply flow diverted to raising the body, supply oil
does not supplement brake cooling pump flow.
 "FLOAT" POSITION
After a load has been dumped, the operator pushes the hoist control
lever downward just below the detent. This is the "FLOAT" position.
To place the hoist control lever in the "FLOAT" position after
being in the "POWER DOWN" position the operator's hand must be
removed from the hoist control lever and the spring force within
the hoist control lever assembly will place the lever at the lower
side of the detent. In the "FLOAT" position the hoist control lever
rheostat will send a 2 volt signal to the hoist controller. The
hoist controller interprets this signal as the "FLOAT" position and
will send a pulsed voltage signal to the Lower PWM valve of the
hoist control valve. The Lower PWM valve shuttles to allow the
hydraulic piloting pressure of 1380-1550 kPa (200-225 psi) to the
end of the hoist control valve spool. The valve spool shifts to
allow the system hydraulic pressure to flow through the hoist
control valve. The hoist cylinder base end oil is open to the
hydraulic tank. When the dump body comes to rest on the frame rail,
the hoist lever is to remain in the "FLOAT" position. In the float
position, supply pump flow passes through the valve after meeting
demands of filling the rod chamber of the hoist cylinders and
supplements brake cooling flow. Oil exiting base chamber of the
hoist cylinders passes through the valve and directly to the
hydraulic tank.
 "HOLD" POSITION

When the dump body is to be held in any one position the

hydraulic control valve lever is moved to the "HOLD" position, or
the third position. When the operator's hand is removed from the
hoist control lever the spring force in the hoist control lever
assembly will place the the lever at the upper side of the
detent, this is the "HOLD" position. In the "HOLD" position the
hoist control lever rheostat will send a 2.5 volt signal to the
hoist controller. The hoist controller interprets this voltage as
the "HOLD" position, and will not send the pulsed voltage signal
to either the Lower or Raise Pulsed Width Modulating valve.
Therefore in this position there isn't a supply of piloting
pressure to the hoist control valve spool. Springs at each end of
the valve spool force the spool to the center position, which
blocks the flow of hydraulic fluid to and from the base end of
the hoist cylinders. The hoist control valve traps the oil in the
base end and the rod end of each hoist cylinder, maintaining the
body in the desired position. Pump supply flow passes through the
valve and supplements the brake cooling circuit.
 "POWER DOWN" POSITION

When the body hoist control valve lever is shifted to the furthest
downward position (all the way down) over coming the the spring
pressure in the hoist lever assembly, this is the "POWER DOWN"
position. In the "POWER DOWN" position a 0.8 volt signal is
directed to the hoist controller. The hoist controller then
interprets this as the "POWER DOWN" position and will send a pulsed
voltage signal to the Lower PWM valve of the hoist control valve.
The Lower PWM valve shuttles to allow hydraulic piloting pressure
of 2068 - 241 5 kPa (300 - 350 psi) to the end of the hoist control
valve spool. The valve spool shifts to allow a reduced amount of
system hydraulic pressure approximately 8300 kPa (1200 psi) to flow
to the rod end of the hoist cylinders, to hydraulically collapse
the cylinders (second stage only) and force the body down. As soon
as the body starts its movement towards the frame rails, the hoist
lever must be moved to the "FLOAT" position to bring the body
completely down. When the dump body comes to rest on the frame
rails, the hoist lever is to remain in the "FLOAT" position.
HYDRAULIC VALVE
CONTROL LEVER
 HYDRAULIC VALVE CONTROL
LEVER POSITIONS

Hoist Hoist EH700/EH1000/EH1100 EH4000/EH4500 Hydraulic

lever lever EH1600/EH1700/EH2000 Hydraulic pilot pilot press kPa (psi)
position operation pressure kPa (psi)
RAISE 4 1725-2070 kPa(250-300psi) 1520-2140 kPa(220-310 psi)
HOLD 3 O kPa (O psi) 0-300 kPa (0-44 psi)
FLOAT 2 1380-1550 kPa(200-225psi) 1083-1430 kPa(157-207psi)
POWER - 1 1725-2415 kPa(250-350psi) 1440-2415 kPa(208-350psi)
DOWN

Hoist Lever Operation

Hydraulic pilot pressures that correspond to the hoist control lever positions
Thank you for your attention
Any Questions?