GLOBAL DEALER LEARNING

798 AC HAA CMD Off-Highway Truck

Hoist System
MODULE 6 - TEXT REFERENCE

SERV2246

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SERV2246 - 12/22 -2- Module 6 - Hoist System

TABLE OF CONTENTS
SAFETY BRIEFING��������������������������������������������������������������������������������������������������������������������� 3
LEARNING OUTCOMES������������������������������������������������������������������������������������������������������������ 4
INTRODUCTION������������������������������������������������������������������������������������������������������������������������� 5
CONTROLS��������������������������������������������������������������������������������������������������������������������������������� 6
HOIST SYSTEM - HOLD������������������������������������������������������������������������������������������������������������� 7
HYDRAULIC TANK��������������������������������������������������������������������������������������������������������������������� 9
HOIST PUMP, OIL FILTERS, AND CONTROL VALVE�������������������������������������������������������������� 10
RIGHT SIDE OF THE HOIST CONTROL VALVE����������������������������������������������������������������������11
LEFT SIDE OF HOIST THE CONTROL VALVE������������������������������������������������������������������������ 12
PILOT CONTROL VALVE���������������������������������������������������������������������������������������������������������� 13
DUAL HOIST RELIEF VALVE��������������������������������������������������������������������������������������������������� 14
BOTTOM OF THE HOIST VALVE��������������������������������������������������������������������������������������������� 15
HOIST CONTROL VALVE - HOLD�������������������������������������������������������������������������������������������� 16
HOIST CONTROL VALVE - RAISE������������������������������������������������������������������������������������������� 17
HOIST COUNTERBALANCE VALVE���������������������������������������������������������������������������������������� 19
HOIST CONTROL VALVE - LOWER (POWER DOWN)����������������������������������������������������������� 20
HOIST CONTROL VALVE - FLOAT������������������������������������������������������������������������������������������� 22
HOIST CYLINDERS������������������������������������������������������������������������������������������������������������������ 23
HOIST HYDRAULIC SYSTEM - HOLD������������������������������������������������������������������������������������� 24
HOIST HYDRAULIC SYSTEM - RAISE������������������������������������������������������������������������������������ 25
HOIST HYDRAULIC SYSTEM - LOWER���������������������������������������������������������������������������������� 26
HOIST HYDRAULIC SYSTEM - FLOAT������������������������������������������������������������������������������������ 27
LEARNING OUTCOMES REVIEW������������������������������������������������������������������������������������������� 28
MODULE CONCLUSION���������������������������������������������������������������������������������������������������������� 29

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SAFETY BRIEFING
• Emergency Phone Numbers
• First Aid Responders
• Location of Exits
• Location of Fire Extinguisher
• Room Alerts or Hazards
• Designated Location for Evacuation
• Storm Shelter
• Hazardous Material

Safely Home. Everyone. Every Day.™

3
SAFETY BRIEFING

Before beginning this module, the following topics will be reviewed:

• Emergency Phone Numbers
• First Aid Responders
• Location of Exits
• Location of Fire Extinguisher
• Room Alerts or Hazards
• Designated Location for Evacuation
• Storm Shelter
• Hazardous Material

Safely Home. Everyone. Every Day.™

NOTE: Any system or component specifications stated in this training

module are used only for training purposes. Components and specifications
may change as the product evolves. Always refer to Caterpillar Service
information to obtain the most current specifications when servicing Cat
products.

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LEARNING OUTCOMES

After completing this Hoist System module of the

798 AC HAA CMD Off-Highway Truck course you
should be able to:
• Locate and identify the components and service points of
the hoist system.
• Test and adjust the components of the hoist system.
• Describe the function and operation of the hoist system
components.

• Learning outcomes LEARNING OUTCOMES

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2 3
5
INTRODUCTION

• Identify the hoist system The hoist system on the 798 AC HAA CMD Trucks is electronically controlled by the
components. Chassis ECM. The hoist system operates similar to many 700 series off-highway
trucks.

The main components in the hoist hydraulic system are:

• Hoist pump (1)
• Hoist oil filters (2)
• Hoist control valve (3)
• Hoist cylinders (4)
• Hydraulic oil tank (5)

The hoist system can be enabled or disabled using Caterpillar Electronic

Technician (Cat ET). All trucks shipped from the factory without bodies are set at
the disabled mode. The disabled mode is a test mode only and will prevent the
hoist cylinders from accidentally being activated. After the body is installed, change
the hoist system to the enabled mode for the hoist system to function properly.

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6
CONTROLS

• Identify the controls. The hoist lever (1) is now located on the shift lever. The hoist control is connected
to the hoist control position sensor located at the base of the lever. The PWM
sensor sends duty cycle input signals to the Chassis ECM. Depending on the
position of the sensor and the corresponding duty cycle, one of the two solenoids
located on the hoist valve is energized.

The four positions of the hoist lever are RAISE, HOLD, FLOAT, and LOWER.
There is a fifth position called SNUB. SNUB is the numerical setting in Cat ET
that controls the speed of the dump body as it gets closer to the frame. A position
sensor (2) is located at the rear of the truck to send the dump body position to the
Chassis ECM.

There is not one number that all trucks use. Many aftermarket bodies may be
lighter or heavier, which would require a different number. Determining the correct
number is up to the technician. A number that allows the body to hit the frame hard
can do damage to the frame, pads, and the body pins. A number that allows the
body to come down too slowly adds to the time the operator has to wait until the
body is completely down on the frame. This can add seconds to each load cycle.

NOTE: If the hoist system fails to function, check the hoist status
configuration in the Chassis ECM.

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Hoist
Pumps (1)

Hoist
Oil Filters
(2)
Pilot Signal Pressure
Generator (9) Reducing Valve (4)

Pump Drive Solenoid Hoist Control Solenoid

Gearbox (10) Valve (5) Valve (3) Valve (5)

Hoist Cylinder Hoist Cylinder

HOIST Rod End (8) Head End (7)

SYSTEM
HOLD
To Rear Brake Oil Cooler (6)

7
HOIST SYSTEM - HOLD

• Identify the hoist system in The hoist system pumps (1) are connected to the pump drive gearbox (10) which is
HOLD. driven by the generator (9) through a short drive shaft.

The hoist system two-section pump pulls oil from the hydraulic tank and sends
the oil through the hoist oil filters (2) to the hoist control valve (3). The pilot signal
pressure reducing valve (4) reduces the oil pressure from the steering pump, which
is used as the pilot oil to shift the directional spool inside the hoist valve.

Two solenoid valves (5) are used to drain the pilot oil to the ends of the directional
spool. The solenoid valve on the left is energized in the RAISE position. The
solenoid valve on the right is energized in the LOWER or FLOAT position. When
the hoist valve is in the HOLD, SNUB, or FLOAT position, all the hoist pump oil
flows to the rear brake oil cooler (6).

An oil cooler relief valve is located in the hoist valve. The relief valve limits the
brake oil cooling pressure when the hoist valve is in the HOLD or FLOAT position.

Two hydraulic cylinders are used to raise the body away from the frame of the
truck. When the hoist lever is held in the RAISE position, supply oil flows to the
head end of the hoist cylinders (7) and moves the two-stage cylinders to their
extended lengths. The oil from the rod end of the cylinders (8) flows through the
hoist valve counterbalance valve and then to tank.

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When the hoist lever is moved to the LOWER or FLOAT position and the cylinders
are extended, supply oil enters the rod end of the hoist cylinders and lowers the
second stage of the cylinders. The oil from the head end of the cylinders flows
through the hoist valve to the hydraulic tank.

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6 5

4
3
7
9
11

8 10
12
9
HYDRAULIC TANK

• Identify the hydraulic tank. The hydraulic tank is located on the left side of the truck.

The tank is typically filled through a quick fill connection located on the front left of
the truck. All the oil is filtered through a remote mounted service filter before it is
directed into the tank.

Components located on the front of hydraulic tank include:

• Engine off, body down sight glass (1)
• Engine running, body down sight glass (2)
• Safe to start with body up sight glass (3)
• Access panel (4)
• Breather port (5), equipped with a protective baffle inside the tank
• Filler neck (6)

A hydraulic low-level sensor (7) and hydraulic temperature switch (8) are on the
front of the hydraulic tank behind a cover (9).

The tank also contains two screens (diffusers) (10), an integrated mud flap (11),
and an auxiliary power unit quick disconnect suction port (12).

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2 3

6
5 7 10
HOIST PUMP, OIL FILTERS, AND CONTROL VALVE

• Identify the hoist pump, oil filters, The tandem two-section hoist pump (1) is a gear-type pump that is connected
and control valve. to the pump drive gearbox (2) and is driven with a drive shaft (3) from the
generator (4). Pump output is directly proportional to the speed of the engine.

Pump oil exits the pump through the outlet ports and flows through hoses to the
high pressure oil filters (5).

The hoist oil filters are mounted inside the right frame rail, to the right of the hoist
control valve (6). The hoist oil filters are equipped with a bypass valve. The bypass
valve limits the maximum differential pressure through the filter element when the
oil is cold, or the filter element is restricted.

The hoist control valve is mounted to a bracket (7) located in front of the rear
axle housing. The hoist control valve directs oil from the hoist pump to the hoist
cylinders.

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6
1 2
7

4 8 5
11
LEFT SIDE OF THE HOIST CONTROL VALVE

• Identify the left side of the hoist The illustration above shows the right side of the hoist control valve. The hoist
control valve. control valve has two functions on the truck. The valve controls the raising and
lowering of the truck body and supplies additional brake cooling oil. When the
hoist control valve is in the HOLD or FLOAT position, supply oil flows to the brake
oil cooling system. As the body is being raised or lowered, the hoist system has
priority and the oil flow to the brake oil cooling system is blocked.

The following components are visible on the left side of the hoist control valve:
• Pilot control valve (lower) (1)
• Pilot control valve (raise) (2)
• Dual stage relief valve (3)
• Head end port (left side cylinder raise control) (4)
• Rod end port (left side cylinder lower control) (5)
• Port (low pressure tank) (6)
• Port (front pump supply) (7)
• Rod end check valve (8)

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2
1

4 8
7
5 6
12
RIGHT SIDE OF HOIST THE CONTROL VALVE

• Identify the right side of the hoist The following components are visible on the left side of the hoist control valve:
control valve.
• Port (rear pump supply) (1)
• Load check valves (2)
• Port (brake oil cooling supply) (3)
• Rod end port (right side cylinder lower control) (4)
• Counterbalance valve (5)
• Plug (counterbalance valve pressure port) (6)
• Head end port (right side cylinder raise control) (7)
• Brake cooling relief valve (8)

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2
3

13
PILOT CONTROL VALVE

• Identify the pilot control valve. The illustration above shows the pilot control valve, which controls the amount of
pilot oil that is used to actuate the main spool (1). In the pilot control valve, the pilot
oil and springs (2) work in tandem to acutate the main spool. The main spool will
remain centered until there is differential between the pilot pressure on each end of
the main spool.

Each pilot control valve is equipped with a proportional coil (3), which uses a
proportional amount of current to shift the valve. As current is applied to the coil,
the valve will shift and trapped oil at the end of the main spool is drained to the
tank. The decrease in oil pressure reduces the force on the main spool and the
spool shifts, which directs oil to the appropriate end of the hoist cylinders.

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1
2
3
4

5
6 7

14
DUAL HOIST RELIEF VALVE

• Identify the dual hoist relief valve. The illustration above shows the location of the dual hoist relief valve components
installed on the top of the hoist valve:
• Dual stage signal spool (1)
• High pressure relief valve seat (2)
• High pressure relief poppet (3)
• High pressure stem (4)
• Low pressure relief valve seat (5)
• Main relief dump spool (6)
• Low pressure relief poppet (7)
• Low pressure stem (8)
NOTE: The high and low pressure relief valve pressure limiting can be
adjusted by adding or removing shims from the appropriate stem.

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1
8

3
4
6
7

15
BOTTOM OF THE HOIST VALVE

• Identify the bottom of the hoist The illustration above shows the lower body of the hoist valve from the bottom. The
valve. body is transparent for ease of viewing the inner components, such as the orifices.
To access the orifices, the green plugs need to be removed.

The components visible from the bottom of the hoist valve are:
• Orifice No.3 (vent orifice for the counterbalance valve) (1)
• Plug (orifice) (2)
• Orifice No.1 (signal orifice for the counterbalance valve) (3)
• Screen (4)
• Plug (orifice) (5)
• Plug (orifice) (6)
• Orifice No. 2 (signal orifice for the counterbalance valve) (7)
• Counterbalance valve (8)

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Lower
Solenoid (3)

Pilot Signal

HOIST CONTROL VALVE

Pressure Reducing
Valve (4)
HOLD

Brake Oil
Tank (16) Cooler Relief
Valve (5)

Hoist Cylinder
Load Check
Head End (6)
Valve (15)

Hoist Cylinder
Rod End (7)

Low Pressure
Relief Valve (14)
Counterbalance
High Pressure Valve (8)
Relief Valve (13) Rod End
Vent Slot (2)
Brake Cooling
Manifold (9)

Dual Stage Main Relief Pump Supply

Relief Valve Dump Spool (12) Port (11)
Signal Stem (1)

Pilot Signal
Pressure Reducing
Valve (4)

Raise
Solenoid (10)

16
HOIST CONTROL VALVE - HOLD

• Identify the hoist control The sectional view above shows the hoist control valve in the HOLD position. Pilot
valve - HOLD condition. oil pressure is directed to both ends of the directional spool. The spool is held in the
centered position by the centering springs and the pilot oil. Passages in the
directional spool vent the dual stage relief valve signal stem (1) to the tank. All the
hoist pump oil flows through the brake cooling port to the oil cooler, to the rear
brakes, and then to tank.

The position of the directional spool blocks the oil in the head end of the hoist
cylinders. Oil in the rod end of the hoist cylinders is connected to the brake cooling
oil by a small rod end vent slot (2) cut in the directional spool.

When the hoist valve is in the HOLD position, the hoist system pressure is at brake
cooling system pressure, which is a result of the restriction in the cooler, brakes,
and hoses (normally lower than the actual oil cooler relief valve setting).The
maximum pressure in the circuit should correspond to the setting of the brake oil
cooler relief valve. The setting of the oil cooler relief valve is approximately 790 kPa
(115 psi).

NOTE: Callouts in the illustration not mentioned in text explanations, and

those in subsequent illustrations, are shown for reference purposes only.

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Lower
Solenoid (3)

Pilot Signal
Pressure Reducing
HOIST CONTROL VALVE Valve (4)

RAISE

Brake Oil
Tank (16) Cooler Relief
Valve (5)

Load Check Hoist Cylinder

Valve (15) Head End (6)

Hoist Cylinder
Rod End (7)

Low Pressure
Relief Valve (14)
Counterbalance
High Pressure Valve (8)
Relief Valve (13) Rod End
Vent Slot (2)
Brake Cooling
Manifold (9)

Dual Stage Main Relief

Relief Valve Pump Supply
Dump Spool (12) Port (11)
Signal Stem (1)

Pilot Signal
Pressure Reducing
Valve (4)

Raise
On
Solenoid (10)
17
HOIST CONTROL VALVE - RAISE

• Identify the hoist control The sectional view above shows the hoist control valve in the RAISE position. The
valve - RAISE condition. raise solenoid (10) is energized and drains pilot oil pressure from the lower end of
the directional spool. The directional spool moves down. Pump oil flows past the
directional spool to the head end of the hoist cylinders.

When the directional spool is initially shifted, the two load check valves (15)
(one shown) remain closed until the pump supply pressure is higher than the
pressure in the hoist cylinders. The load check valves prevent the body from
dropping before the raise pressure increases.

The directional spool also sends hoist cylinder raise pressure to the dual stage
relief valve signal stem (1) and the counterbalance valve (8). The dual stage relief
valve signal stem moves down and blocks the supply pressure from opening the
low pressure relief valve.

The counterbalance valve is held open by the hoist cylinder raise pressure. Oil from
the rod end of the hoist cylinders flows freely to the brake cooling manifold (9). If
the body raises faster than the pump can supply oil to the hoist cylinders
(caused by a sudden shift of the load) and the raise pressure drops below
approximately 2275 kPa (330 psi), the counterbalance valve starts to close and
restricts the flow of oil from the rod end of the hoist cylinders. Restricting the flow of
oil from the rod end of the hoist cylinders will slow down the cylinders and prevent
cavitation.

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Cavitation in the hoist cylinders can cause the body to drop suddenly when the
hoist lever is moved from the RAISE position to the LOWER position.

The high pressure relief valve will open if the pressure in the head of the hoist
cylinders is too high. When the high pressure relief valve opens, the dump spool
moves to the left, and pump oil is directed to the brake cooling manifold.

The high pressure hoist relief valve setting should be checked at the hoist valve
supply pressure tap downstream of the high pressure filters. Check the relief
pressures with the hoist lever in the RAISE position and the engine at HIGH IDLE.

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HOIST
COUNTERBALANCE
VALVE

Head End Signal

Pressure (1)

Tank Pump
(2) (6)

Hoist Cylinder
Rod End (4) Rod End
Pressure
Hoist Cylinder
Piston (3)
Rod End (8) Check Valve (7)

RAISE (5) LOWER AND FLOAT (9)

19
HOIST COUNTERBALANCE VALVE

• Identify the hoist counterbalance During RAISE, the hoist counterbalance valve prevents the dump body from
valve. running ahead of the hoist pumps if the load shifts rapidly to the rear of the body
and attempts to pull the hoist cylinders. Signal pressure from the head end of the
hoist cylinders holds the counterbalance valve open. Oil from the rod end of the
hoist cylinders flows unrestricted through the counterbalance valve to the tank. If
the head end pressure decreases below 2270 kPa (330 psi), the counterbalance
valve moves down and restricts the flow of oil from the rod end of the cylinders to
the tank.

If no head end signal pressure is present, the rod end pressure can still open the
hoist counterbalance valve. If the rod end pressure exceeds approximately
6900 ± 690 kPa (1000 ± 100 psi) at the rod end pressure piston, the valve will
move up and allow rod end oil to flow from the cylinders to the tank.

During LOWER and FLOAT, the hoist counterbalance valve allows unrestricted oil
flow from the pump, through a check valve (7), to the rod end of the hoist cylinders.

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SERV2246 - 12/22 -20- Module 6 - Hoist System

Lower On
Solenoid (3)

Pilot Signal
Pressure Reducing
HOIST CONTROL VALVE Valve (4)
LOWER (POWER DOWN)

Brake Oil
Cooler Relief
Tank (16) Valve (5)

Hoist Cylinder
Load Check Head End (6)
Valve (15)

Hoist Cylinder
Rod End (7)

Low Pressure
Relief Valve (14)
Counterbalance
High Pressure Valve (8)
Relief Valve (13) Rod End
Vent Slot (2)
Brake Cooling
Manifold (9)

Dual Stage Main Relief Pump Supply

Relief Valve Dump Spool (12) Port (11)
Signal Stem (1)

Pilot Signal
Pressure Reducing
Valve (4)

Raise
Solenoid (10)
20
HOIST CONTROL VALVE - LOWER (POWER DOWN)

• Identify the hoist control The sectional view above shows the hoist control valve in the LOWER (power
valve - LOWER (power down) down) position. The lower solenoid (3) is energized and drains pilot oil pressure
condition. from the upper end of the directional spool. The directional spool moves up.

Supply oil from the pump flows past the directional spool, through the
counterbalance valve, to the rod end of the hoist cylinders. Oil in the head end of
the hoist cylinders flows to the tank. The supply oil in the rod end of the cylinders
and the weight of the body move the cylinders to their retracted positions.

Just before the body contacts the frame, the body position sensor sends a signal
to the Chassis ECM to move the valve spool to the SNUB position. In the SNUB
position, the valve spool moves slightly to restrict the flow of oil and lowers the
body gently.

The directional spool also vents the passage to the dual stage relief valve signal
stem. The dual stage relief valve signal stem allows supply pressure to be limited
by the low pressure relief valve.

If the pressure in the rod end of the hoist cylinders exceeds approximately
3450 kPa (500 psi), the low pressure relief valve (14) will open. When the low
pressure relief valve opens, the dump spool moves to the left and pump oil flows to
the brake cooling manifold (9).

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The low pressure hoist relief valve setting should be checked at the hoist valve
supply pressure tap downstream of the high pressure filters. Check the relief
pressures with the hoist lever in the LOWER position and the engine at HIGH IDLE.

When the body is in the DOWN position, the hoist control valve will be in the SNUB
position. The body position sensor rod must be disconnected from the body, and
the sensor must be rotated to the RAISE position before the lower relief pressure
can be tested.

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Lower On
Solenoid (3)

Pilot Signal
Pressure Reducing
HOIST CONTROL VALVE Valve (4)
FLOAT

Brake Oil
Tank (16) Cooler Relief
Valve (5)

Hoist Cylinder
Load Check
Head End (6)
Valve (15)

Hoist Cylinder
Rod End (7)

Low Pressure
Relief Valve (14)
Counterbalance
High Pressure Valve (8)
Relief Valve (13) Rod End
Vent Slot (2)
Brake Cooling
Manifold (9)

Dual Stage Main Relief Pump Supply

Relief Valve Dump Spool (12) Port (11)
Signal Stem (1)

Pilot Signal
Pressure Reducing
Valve (4)

Raise
Solenoid (10)
22
HOIST CONTROL VALVE - FLOAT

• Identify the hoist control The sectional view above shows the hoist control valve in the FLOAT position. The
valve - FLOAT condition. lower solenoid (3) is partially energized and drains part of the pilot oil pressure
above the directional spool to the tank. The directional spool moves up. Because
the pilot pressure is only partially drained, the directional spool does not move as
far up as during the LOWER position.

Pump supply oil flows past the directional spool, through the counterbalance
valve (8), to the rod end of the hoist cylinders (7). Oil in the head end of the hoist
cylinders (6) flows to the tank. The directional valve is in a position that permits the
pressure of the oil flowing to the brake cooling manifold (9) to be felt at the rod end
of the hoist cylinders.

The truck should normally be operated with the hoist lever in the FLOAT position.
Traveling with the hoist in the FLOAT position will make sure the weight of the body
is on the frame and body pads and not the hoist cylinders. The hoist valve will
actually be in the SNUB position.

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HOIST CYLINDERS - RAISE HOIST CYLINDERS - LOWER

23
HOIST CYLINDERS

• Identify the hoist cylinders. The hoist cylinders are two-stage, double-acting hydraulic cylinders. The hoist
cylinders raise and lower the dump body. The cylinders are positioned to lift the
front of the dump body, which pivots at the rear. The oil is directed in and out of the
cylinders through a pair of ports on the rod end of the cylinder.

To raise the dump body (extend the cylinders), the hydraulic oil is directed from the
hoist valve into the extend port (head end) of each cylinder. The oil moves up the
center tube, pressurizing the first and second stage pistons of each cylinder, which
cause the cylinders to extend. The first and second stage extend together until the
first stage bottoms out. The second stage then extends out from the first stage.

The oil from the rod end of the cylinder flows out through the retract lines in the
center tubes, exits through the retract port, and returns to the hydraulic tank
through the hoist valve. In the lower (retraction) mode, the pressurized oil is routed
into the cylinder retract ports and to the rod end of the cylinders. The second stage
retracts first, followed by the first stage. The oil from the head end of the cylinder
exits through the raise connection and to the hydraulic tank, through the hoist
valve.

NOTE: These illustrations are from a 700 series Service Training Meeting
Guide and do not show the true representation of the MT series hoist
hydraulic cylinder. The major difference is where the rod and head oil
connections are located at the bottom of the cylinder.

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SERV2246 - 12/22 -24- Module 6 - Hoist System

HOIST SYSTEM
Steering Pump (37)
HOLD
Steering Priority
Valve (36) SW P A

T
Priority Valve (38) Hoist Control Valve (7)

S1 Left Hoist Cylinder (21) Right Hoist Cylinder (22)

F
Counterbalance Valve (20)
Raise
B Solenoid
Hoist Boost R Valve (8)
Solenoid (35) R1

LOWER (10)
R2
FLOAT (11)
Hoist Boost Valve (23)
T SNUB (12)
A1 H1
HOLD (13)
A2
RAISE (14) H2
C1
C2
S2

Pump Drive Gearbox (3) Brake Cooling Relief Valve (19)

Gearbox Pumps (6)
Lower
Solenoid
Low Pressure Relief Valve (18)
Valve (9)

Steering Pump (4) High Pressure Relief Right Brake Cooling Oil
Right Rear Wheel
Valve (17) Temperature Sensor (26)
Brake Housing (25)
Engine Radiator
Fan Pump (5) Main Relief Dump Spool (15) Hydraulic Oil Cooler (24)

Dual Stage Signal Spool (16)

SOS
To Engine Radiator Fan Pump
Hoist Filters With Left Brake Cooling Oil
Visual Indicator (2) Hoist Pumps (1) Temperature Sensor (27)

3 2
1 From Steering Manifold From
Breather (32) Engine Auxiliary
Coolant Pump
Hoist Pressure
Reducing Valve (29) Left Rear Wheel
Brake Housing (28)
To Front Brake Cooling
Oil Level Sensor (34)
From Engine Radiator Fan Pump

Oil Temperature
Switch (33)

Diffusers (31)
Hydraulic Tank (30) From Steering Pump
24
HOIST HYDRAULIC SYSTEM - HOLD

• Identify the hoist hydraulic The hoist system hydraulic schematic above shows the hoist lever in the HOLD
system - HOLD position. position.

Oil from the steering system manifold flows to the hoist pressure reducing
valve (29). The pressure reducing valve reduces the steering system oil pressure to
pilot pressure. The pilot oil flows to both ends of the hoist control valve spool. The
dual-section hoist pump (1) provides oil flow to the hoist control valve spool, and in
the HOLD position, this oil is blocked from the hoist cylinders (21 and 22). Oil flow
is also directed to the main relief dump spool (15) and the dual stage signal
spool (16). From the dual stage signal spool, oil is directed to the low pressure
relief valve (18) and the high pressure relief valve (17). With the hoist spool in the
HOLD position, oil passes around the spool to the hydraulic oil cooler (24) for rear
brake cooling.

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SERV2246 - 12/22 -25- Module 6 - Hoist System

HOIST SYSTEM
Steering Pump (37) RAISE
Steering Priority
Valve (36) SW P A

T
Priority Valve (38) Hoist Control Valve (7)

S1 Left Hoist Cylinder (21) Right Hoist Cylinder (22)

F
Raise Counterbalance Valve (20)
B Solenoid
Valve (8)
Hoist Boost R
Solenoid (35) R1

LOWER (10)
R2
FLOAT (11)
Hoist Boost Valve (23)
T SNUB (12)
A1 H1
HOLD (13)
A2
RAISE (14) H2
C1
C2
S2

Pump Drive Gearbox (3) Brake Cooling Relief Valve (19)

Gearbox Pumps (6)
Lower
Solenoid
Low Pressure Relief Valve (18)
Valve (9)

Steering Pump (4) High Pressure Relief Right Rear Wheel Right Brake Cooling Oil
Valve (17) Brake Housing (25) Temperature Sensor (26)
Engine Radiator
Fan Pump (5) Main Relief Dump Spool (15) Hydraulic Oil Cooler (24)

Dual Stage Signal Spool (16)

SOS
To Engine Radiator Fan Pump
Hoist Filters With Left Brake Cooling Oil
Visual Indicator (2) Hoist Pumps (1) Temperature Sensor (27)

3 2
1 From Steering Manifold From
Breather (32) Engine Auxiliary
Coolant Pump
Hoist Pressure
Reducing Valve (29) Left Rear Wheel
Brake Housing (28)
To Front Brake Cooling
Oil Level Sensor (34)
From Engine Radiator Fan Pump

Oil Temperature
Switch (33)

Hydraulic Tank (30) Diffusers (31)

From Steering Pump
25
HOIST HYDRAULIC SYSTEM - RAISE

• Identify the hoist hydraulic The hoist system hydraulic schematic above shows the hoist lever in the RAISE
system - RAISE position. position.

In the RAISE position, the raise solenoid valve (8) is energized and drains pilot oil
to the tank. Pilot oil at the lower solenoid valve (9), at the opposite end of the spool,
moves the spool up to the RAISE (14) position. Oil from the hoist pumps (1) is then
directed to the head end of the hoist cylinders (21 and 22). Return oil from the hoist
cylinders then flows to the counterbalance valve (20). The counterbalance valve
ensures both hoist cylinders extend at the same rate. From the counterbalance
valve, oil is then directed through the hoist spool and to the hydraulic oil
cooler (24).

When the hoist lever is moved to the RAISE position, the Chassis ECM also
energizes the hoist boost solenoid (35) located in the steering priority valve (36).
The hoist boost solenoid activates the hoist boost valve (23). The hoist boost valve
directs oil flow from steering pump (37), which combines with oil from the hoist
pumps to supplement the hoist circuit oil flow and reduce cycle times. The steering
system priority valve (38) will always give priority to the steering system.

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SERV2246 - 12/22 -26- Module 6 - Hoist System

Steering Pump (37) HOIST SYSTEM

Steering Priority
LOWER
Valve (36) SW P A

T
Priority Valve (38) Hoist Control Valve (7)

S1 Left Hoist Cylinder (21) Right Hoist Cylinder (22)

F Counterbalance Valve (20)
Raise
B Solenoid
R Valve (8)
Hoist Boost
Solenoid (35) R1

LOWER (10)
R2
FLOAT (11)
Hoist Boost Valve (23)
T SNUB (12)
A1 H1
HOLD (13)
A2
RAISE (14) H2
C1
C2
S2

Pump Drive Gearbox (3) Brake Cooling Relief Valve (19)

Gearbox Pumps (6)
Lower
Solenoid
Valve (9) Low Pressure Relief Valve (18)

Steering Pump (4) High Pressure Relief Right Brake Cooling Oil
Right Rear Wheel
Valve (17) Temperature Sensor (26)
Brake Housing (25)
Engine Radiator
Fan Pump (5) Main Relief Dump Spool (15) Hydraulic Oil Cooler (24)

Dual Stage Signal Spool (16)

SOS
To Engine Radiator Fan Pump
Hoist Filters With Left Brake Cooling Oil
Visual Indicator (2) Hoist Pumps (1) Temperature Sensor (27)

3 2
1 From Steering Manifold From
Engine Auxiliary
Breather (32) Coolant Pump
Hoist Pressure
Reducing Valve (29) Left Rear Wheel
Brake Housing (28)
To Front Brake Cooling
Oil Level Sensor (34)
From Engine Radiator Fan Pump

Oil Temperature
Switch (33)

Diffusers (31) From Steering Pump

Hydraulic Tank (30)

26
HOIST HYDRAULIC SYSTEM - LOWER

• Identify the hoist hydraulic The hoist system hydraulic schematic above shows the hoist lever in the LOWER
system - LOWER position. position.

In the LOWER position, the lower solenoid valve (9) is energized and drains pilot oil
to the tank. Pilot oil at the raise solenoid valve (8), at the opposite end of the spool,
moves the spool to the LOWER (10) position. Oil from the hoist pumps (1) is then
directed to the rod end of the hoist cylinders (21 and 22). Return oil from the hoist
cylinders then flows to the tank. Oil from the hoist pumps that is not needed for the
LOWER circuit is directed through the hoist spool and to the hydraulic oil
cooler (24).

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SERV2246 - 12/22 -27- Module 6 - Hoist System

HOIST SYSTEM
Steering Pump (37)
FLOAT
Steering Priority
Valve (36) SW P A

T
Priority Valve (38) Hoist Control Valve (7)

S1 Left Hoist Cylinder (21) Right Hoist Cylinder (22)

F
Raise Counterbalance Valve (20)
B Solenoid
R Valve (8)
Hoist Boost
Solenoid (35) R1

LOWER (10)
R2
FLOAT (11)
Hoist Boost Valve (23)
T SNUB (12)
A1 H1
HOLD (13)
A2
RAISE (14) H2
C1
C2
S2

Pump Drive Gearbox (3) Brake Cooling Relief Valve (19)

Gearbox Pumps (6)
Lower
Solenoid
Low Pressure Relief Valve (18)
Valve (9)

Right Rear Wheel Right Brake Cooling Oil

Steering Pump (4) High Pressure Relief
Valve (17) Brake Housing (25) Temperature Sensor (26)
Engine Radiator
Fan Pump (5) Main Relief Dump Spool (15) Hydraulic Oil Cooler (24)

Dual Stage Signal Spool (16)

SOS
To Engine Radiator Fan Pump
Hoist Filters With Left Brake Cooling Oil
Visual Indicator (2) Hoist Pumps (1) Temperature Sensor (27)

3 2
1 From Steering Manifold From
Breather (32) Engine Auxiliary
Coolant Pump
Hoist Pressure Left Rear Wheel
Reducing Valve (29) Brake Housing (28)
To Front Brake Cooling
Oil Level Sensor (34)
From Engine Radiator Fan Pump

Oil Temperature
Switch (33)

Hydraulic Tank (30) Diffusers (31)

From Steering Pump

27
HOIST HYDRAULIC SYSTEM - FLOAT

• Identify the hoist hydraulic The hoist system hydraulic schematic above shows the hoist lever in the FLOAT
system - FLOAT position. position.

In the FLOAT position, the lower solenoid valve (9) is energized and drains pilot oil
to the tank. Pilot oil at the raise solenoid valve (8), at the opposite end of the spool,
moves the spool to the FLOAT (11) position. Oil from the hoist pumps (1) is then
directed to the rod end of the hoist cylinders (21 and 22). Return oil from the hoist
cylinders then flows to the tank. Oil from the hoist pumps that is not needed for the
FLOAT circuit is directed through the hoist spool and to the hydraulic oil cooler (24).

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SERV2246 - 12/22 -28- Module 6 - Hoist System

LEARNING OUTCOMES

Now that you have completed this Hoist System

module of the 798 AC HAA CMD Off-Highway Truck
course you should be able to:
• Locate and identify the components and service points of
the hoist system.
• Test and adjust the components of the hoist system.
• Describe the function and operation of the hoist system
components.

28

• Learning outcomes review LEARNING OUTCOMES REVIEW

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SERV2246 - 12/22 -29- Module 6 - Hoist System

29
MODULE CONCLUSION

• Conclusion This concludes the Hoist System module for the 798 AC HAA CMD Off-Highway
Truck course.

When used in conjunction with the service manuals, the information in this module
will aid the service technician in troubleshooting, testing, adjusting, and correcting
problems with the machine.

For service repairs, adjustments, and maintenance, always refer to the Operation
and Maintenance Manual (OMM), service manuals, and other related service
publications.

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