Service Training

MALAGA

777D Off Highway Truck

STEERING SYSTEM HAND CROSSOVER

METERING UNIT (HMU) RELIEF VALVES
HOLD
ELECTRONIC
CONTROL
MODULE
STEERING
HYDRAULIC
TANK

OIL
FILTER MAIN
RELIEF
MAGNETIC
SWITCH CHECK
VALVE

SECONDARY
STEERING
PUMP CHECK
VALVE

FLOW
SWITCH

ACCUMULATOR
STEERING
PUMP
STEERING
FLOW CYLINDERS
CONTROL VALVE

VII STEERING.
1. Components Layout
2. Operation
3. Maintenance
4. Testing & Adjusting
Adolfo
August 1997
 777D Off Highway Truck
CHAPTER : STEERING

TYPICAL OFF-HIGHWAY TRUCK STEERING

COMPONENT LOCATIONS
FLOW
SECONDARY CONTROL
STEERING VALVE
PUMP
STEERING
ELECTRIC CYLINDERS
MOTOR
STEERING
PUMP
HYDRAULIC
TANK

HMU

STEERING
ECM HOIST PUMP
OIL FILTER ACUMULATOR

HMU

CROSSOVER
RELIEF
VALVES STEERING
PUMP

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VI-2

STEERING SYSTEM HAND CROSSOVER

METERING UNIT (HMU) RELIEF VALVES
HOLD
ELECTRONIC
CONTROL
MODULE
STEERING
HYDRAULIC
TANK

OIL

CHAPTER : STEERING
FILTER MAIN
RELIEF
MAGNETIC
SWITCH CHECK

777D Off Highway Truck

VALVE

SECONDARY
STEERING
PUMP CHECK
VALVE

FLOW
SWITCH

ACCUMULATOR
STEERING
PUMP
STEERING
FLOW CYLINDERS
CONTROL VALVE
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VI-3

STEERING SYSTEM HAND CROSSOVER

RIGHT TURN METERING UNIT (HMU) RELIEF VALVES

ELECTRONIC
CONTROL
MODULE

STEERING
HYDRAULIC
TANK

OIL
FILTER

CHAPTER : STEERING
MAGNETIC
SWITCH

777D Off Highway Truck

SECONDARY
STEERING
PUMP

ACCUMULATOR
FLOW
STEERING CONTROL VALVE
PUMP
STEERING
CYLINDERS
 777D Off Highway Truck
CHAPTER : STEERING

STEERING FLOW
CONTROL VALVE

TO
HMU

MAIN
RELIEF
VALVE CHECK
VALVE

FROM
HMU

FLOW
CONTROL
ORIFICE

TO CHECK
TANK VALVE

CHECK VALVE

FROM
SIGNAL TO SECONDARY
SECONDARY STEERING PUMP
STEERING

FLOW SWITCH FROM PUMP

CLOSED

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HAND METERING UNIT

VI-5

HOLD

STATIONARY COMMUTATOR
BALL IN GEAR
HELICAL
GROOVE
INPUT SHAFT

CHAPTER : STEERING
777D Off Highway Truck
TORSION BAR

VALVE SPOOL TO TO ROTATING

TO
TANK CYLINDER CYLINDER GEAR

FROM
PUMP DRIVE
LINK
Page:

HAND METERING UNIT

VI-6

LEFT TURN

COMMUTATOR
STATIONARY
GEAR
BALL

INPUT SHAFT

CHAPTER : STEERING
777D Off Highway Truck
TORSION BAR

TO FROM
VALVE SPOOL TANK
TO PUMP
CYLINDER
FROM
CYLINDER ROTATING DRIVE
GEAR LINK
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VI-7

HAND METERING UNIT

RIGHT TURN

STATIONARY
GEAR
COMMUTATOR

BALL
INPUT SHAFT

CHAPTER : STEERING
777D Off Highway Truck
TORSION BAR

FROM
VALVE SPOOL CYLINDER DRIVE
ROTATING LINK
TO GEAR
TANK FROM
TO PUMP
CYLINDER
 777D Off Highway Truck
CHAPTER : STEERING

CROSSOVER RELIEF SYSTEM

EXTERNAL IMPACT

CROSSOVER
RELIEF VALVES

HAND
METERING UNIT

Page: VI-8
 777D Off Highway Truck
CHAPTER : STEERING

LAB EXERCISES
LAB A: STEERING SYSTEM COMPONENT IDENTIFICATION

Directions: Place the correct letter or number next to the component and briefly describe the
function of each.

Steering System Components

Flow Control Valve and Flow Switch

Hand Metering Unit

Oil Filter

Steering Pump

Secondary Steering Electronic Control Module

Secondary Steering Magnetic Switch

Secondary Steering Pump

Crossover Relief Valves

Accumulator (777D truck only)

Steering Hydraulic Tank

Page: VI-9
 777D Off Highway Truck
CHAPTER : STEERING

LAB EXERCISES
LAB B: STEERING SYSTEM TESTING

Machine Model __________________________ Date_______________________________

Serial Number ___________________________ Technician___________________________

VISUAL CHECKS:

Oil level _______________ Oil Viscosity _______________ Oil leaks ? ______________

Air/Water in Oil ?_______ Suction Screen Debris ? _______ Oil Filter Examination ______

PRESSURE TESTS

TEST SPECIFICATIONS ACTUAL

Full Cycle Time at High Idle

Main Relief Valve Pressure (Left Turn) at High Idle

Main Relief Valve Pressure (Right Turn) at High Idle

Crossover Relief Valve (Left Turn) at Low Idle

Crossover Relief Valve (Right Turn) at Low Idle

Accumulator Charge Pressure

SECONDARY STEERING SYSTEM TEST

The truck should be on flat level ground with the parking brake engaged. Turn the ignition
switch ON (engine off) and actuate the secondary pump automatic/manual switch to the
MANUAL position. Then, attempt to turn the steering wheel. You should be able to hear the
secondary pump motor run and the front wheels of the truck should turn.

Page: VI-10
 777D Off Highway Truck
CHAPTER : STEERING

LAB EXERCISES
LAB C: TRACING STEERING SYSTEM OIL FLOW

I. Directions: Have each student trace the flow of oil during the conditions listed below
using different colored pencils to show each path:

• Steering system when the steering wheel is stationary

• Steering system when the steering wheel is turned to the right or left

HAND CROSSOVER
METERING UNIT (HMU) RELIEF VALVES

STEERING
HYDRAULIC
TANK

OIL
FILTER

STEERING
CYLINDERS
SECONDARY
STEERING
PUMP

ACCUMULATOR

FLOW
CONTROL VALVE

STEERING PUMP

HAND CROSSOVER
METERING UNIT (HMU) RELIEF VALVES

STEERING
HYDRAULIC
TANK

OIL
FILTER

STEERING
CYLINDERS
SECONDARY
STEERING
PUMP

ACCUMULATOR

FLOW
CONTROL VALVE

STEERING PUMP

Page: VI-11
 777D Off Highway Truck
CHAPTER : STEERING

LAB EXERCISES
LAB C: TRACING STEERING SYSTEM OIL FLOW (CONT.)

II. Directions: Have each student trace the flow of oil during the conditions listed below
using different colored pencils to show each path:

• Flow control valve under normal conditions

• Flow control valve when the secondary steering system is in operation
• Flow control valve when system pressure exceeds the setting of the main relief valve.

Page: VI-12
 777D Off Highway Truck
CHAPTER : STEERING

LAB EXERCISES

LAB D: STEERING SYSTEM TROUBLESHOOTING

Machine Model __________________________ Date_______________________________

Serial Number ___________________________ Technician___________________________

VISUAL CHECKS:

Oil level _______________ Oil Viscosity _______________ Oil leaks ? ______________

Air/Water in Oil ?_______ Suction Screen Debris ? _______ Oil Filter Examination ______

PRESSURE TESTS

TEST SPECIFICATIONS ACTUAL

Full Cycle Time at High Idle

Main Relief Valve Pressure (Left Turn) at High Idle

Main Relief Valve Pressure (Right Turn) at High Idle

Crossover Relief Valve (Left Turn) at Low Idle

Crossover Relief Valve (Right Turn) at Low Idle

Accumulator Charge Pressure

Page: VI-13
 777D Off Highway Truck
CHAPTER : STEERING

POST TEST
Off-Highway Trucks Steering System Posttest

I. Directions: Match the component to the correct statement below.

1. Crossover Relief Valves 5. Steering Hydraulic Tank
2. Oil Filter 6. Secondary Steering Pump
3. Flow Control Valve 7. Flow Switch
4. Hand Metering Unit 8. Accumulator

Dampens pressure surges in the steering system.

Contains an oil filter.

Contains a check valve to prevent pressure surges from the steering cylinders from
returning to the HMU when a turn is in progress.

Meters and redirects oil to the steering cylinders as the steering wheel is turned.

Equalizes the pressure in both steering cylinders if the pressure in one cylinder exceeds
the relief valve setting.

Utilizes a bypass valve to protect the steering system during cold oil start-up.

Is energized by a magnetic switch.

Indicates to the electronic control module a loss of oil flow.

II. Directions: Indicate whether the statement is True or False by circling the corresponding
letter.

1. The secondary steering motor is tested every time the ignition switch is turned to the ON
position. (T) or F

2. The crossover relief valve pressure setting is higher than the setting of the main steering
relief valve (in the flow control valve). (T) or F

3. The crossover relief valves should be checked at low idle and are adjustable. T or (F)

4. When the steering wheel is stationary, steering oil circulates through the Hand Metering
Unit (HMU), back to the steering hydraulic tank, and oil flow is blocked to and from the
steering cylinders. (T) or F

5. All truck models are equipped with an accumulator that uses a nitrogen gas charge to
cushion the steering system from pressure surges. T or (F)

Page: VI-14
 777D Off Highway Truck
CHAPTER : STEERING

POST TEST
III. Directions: Match the components with the associated letter.

STEERING SYSTEM

A
I

E F

H
K

G
C

Flow Control Valve Hand Metering Unit

Oil Filter Steering Pump

Crossover Relief Valves Steering Cylinders

Secondary Steering Pump Accumulator

Steering Hydraulic Tank Magnetic Switch

Automatic/Manual Panel Switch Electronic Control Module

Page: VI-15
 777D Off Highway Truck
CHAPTER : STEERING

POST TEST
IV. Directions: Match the components and ports with the associated letter.

FLOW CONTROL VALVE

Flow Switch From Hand Metering Unit

To Hand Metering Unit Steering Pump Inlet

Relief Valve Flow Control Orifice

Secondary Steering Pump Inlet To Steering Hydraulic Tank

G
F
Page: VI-16