GLOBAL MANPOWER DEVELOPMENT

773G/775G OFF-HIGHWAY TRUCK

STEERING SYSTEM
MODULE 6 - TEXT REFERENCE

SERV1921

Print Instructor Pages Print Participant Pages

© 2011 Caterpillar Inc.

Caterpillar: Confidential Yellow
SERV1921 - 09/11 -2- Module 6 - Steering System

4
2 1

5 6
7
2_1

INTRODUCTION

Steering system components The steering system on the 773G/775G is similar to the 773F/775F except the
steering disable valve has been combined with the steering control valve into one
valve block assembly called the steering control manifold.

When energized, the steering disable solenoid valve stops the oil flow coming from
the steering pump. This prevents the front wheels from turning to allow servicing to
be conducted safely in the front wheel area.

The steering system uses a load sensing, pressure compensated pump. Minimal
horsepower is used by the steering system when the truck is traveling in a straight
path. Steering hydraulic horsepower requirements depend on the amount of steering
pressure and flow required by the steering cylinders.

This image shows the following main steering components:

• Steering pump (1) • Steering tank (4)

• Steering control manifold • Secondary steering motor and

(2) pump (5)

• HMU (3) • Left side steering cylinder (6)

• Steering system return oil filter (7)

Caterpillar: Confidential Yellow

SERV1921 - 09/11 -3- Module 6 - Steering System

4 3

5 2
1
6

8
3_1

STEERING SYSTEM COMPONENTS

Right platform view of steering The steering system tank (2) is located on the right platform.
components
Check the steering system oil level at the sight gauge on the front of the tank (not
shown).

The steering pump case drain oil filter (5) is located on the back side of the steering
tank and is accessible from the top of the truck. The change interval has been
increased from 500 hours to 3000 hours. Case drain oil from the steering pump
returns to the hydraulic tank through the case drain filter.

Before removing the steering system oil cap (3) to add oil to the steering system,
depress the pressure release button on the top of the breather (4) to release any
remaining pressure from the tank.

The steering system return oil filter base and the case drain filter base have bypass
valves that allow the steering oil to bypass the filters if they are plugged.

Additional components:

• HMU (1)
• Steering control manifold (7)
• Steering pump (6)
• Right side steering cylinder (8)
Caterpillar: Confidential Yellow
SERV1921 - 09/11 -4- Module 6 - Steering System

2
1

4_1

Steering oil level sensors The steering oil level is monitored by the Transmission/Chassis ECM via three
sensors located on the inboard side of the steering tank.

The three steering oil level sensors each send a signal to the Transmission/Chassis
ECM indicating the steering tank oil level.

The steering oil level sensors are:

• LOW (1)

• FILL (2)

• FULL (3)

Caterpillar: Confidential Yellow

SERV1921 - 09/11
3 1
Steering pump components
-5- Module 6 - Steering System
5_1
The 773G/775G Trucks are equipped with a load sensing, pressure compensated,
piston-type pump (1). The steering pump operates only when the engine is running
and provides the necessary flow of oil for steering system operation. The steering
pump contains a load sensing controller with two valves. The high pressure cutoff
valve (2) functions as the primary steering system relief valve and is set to
approximately 21200 kPa (3100 psi).
The flow compensator valve (3) is used to adjust the low pressure standby setting.
When the truck is traveling in a straight path, virtually no flow or pressure is sent to
the steering cylinders, and the pump destrokes to low pressure standby.
Caterpillar: Confidential Yellow
SERV1921 - 09/11 -6- Module 6 - Steering System

(8) Load Sensing

Pressure
(7) To Steering
Valve
STEERING PUMP
from HMU and HMU LOW PRESSURE STANBY

(6) High Pressure

Cutoff Valve (4) Actuator Piston

(1) Flow
Compensator

(2) Load Sensing

Controller
(3) Swashplate
Piston
(5) Case
Drain Filter

6_1

Steering pump - LOW PRESSURE When the truck is traveling in a straight path, the steering cylinders require virtually
STANDBY no flow or pressure. The HMU provides a very low pressure load sensing signal to
the flow compensator (1) in the load sensing controller (2).

Pump oil (at low pressure standby) flows to the swashplate piston (3) and past
the lower end of the displaced flow compensator spool to the actuator piston (4).
The actuator piston has a larger surface area than the swashplate piston. The oil
pressure at the actuator piston overcomes the spring force plus the oil pressure in
the swashplate piston, which moves the swashplate to destroke the pump. The
pump is then at minimum flow, low pressure standby.

Pump output pressure is equal to the setting of the flow compensator plus the
pressure required to compensate for system leakage and the dynamic load sensing
signal oil.

Caterpillar: Confidential Yellow

SERV1921 - 09/11 -7- Module 6 - Steering System

(8) Load Sensing

Pressure
(7) To Steering
Valve
STEERING PUMP
from HMU and HMU MAXIMUM FLOW
(6) High Pressure
Cutoff Valve
(4) Actuator Piston

(1) Flow
Compensator

(2) Load Sensing

Controller

(3) Swashplate
Piston
(5) Case
Drain Filter

7_1

Steering pump - MAXIMUM FLOW
During a turn, when steering pressure and flow are required, pressure increases in
the HMU load sensing signal line. The pressure in the signal line is approximately
equal to the pressure in the steering cylinders. The pump load sensing controller (2)
is spring biased to vent the actuator piston (4) pressure to drain. Venting pressure
from the load sensing controller and the actuator piston positions the spring biased
swashplate to maximum displacement (maximum flow).

As pressure increases in the HMU load sensing signal line, pump supply pressure is
sensed on both ends of the flow compensator (1). When pressure is present on both
ends of the flow compensator, the swashplate is kept at maximum angle by the force
of the spring in the pump housing and pump discharge pressure on the swashplate
piston (3). The pistons reciprocate in and out of the barrel and maximum flow is
provided through the outlet port. Since the pump is driven by the engine, engine rpm
also affects pump output.

Caterpillar: Confidential Yellow

SERV1921 - 09/11 -8- Module 6 - Steering System

STEERING HYDRAULIC SYSTEM

RIGHT TURN
(6) Steering
Tank (1) Steering
(5) Steering
Cylinders
Filter
(11) Case T L
Drain
Filter
LS
P R

(4)
HMU
(7) Brake
(9) Secondary Retract
Steering Pump Pump (3) Steering System
Pressure Tap
(12) Steering
Pump M
(10) Secondary Steering &
Brake Retract Motor
(8) Load Sensing
Valve & Relief Valve

(2) Steering Control Manifold

8_1
Steering Hydraulic System - RIGHT This illustration shows the operator turning the steering wheel to the right to make a
TURN right turn. Oil from the steering pump (12) is directed to the steering control manifold
(2) before it goes to the hand metering unit (HMU) (4) and then to the two steering
cylinders (1).

The steering control manifold has two basic purposes: one is to provide primary and
secondary system relief and the second is to direct steering pump oil or, if the engine
is off, direct oil from the electric driven secondary steering pump (9) to the HMU.

As the HMU is rotated, load sensing oil (orange) is directed through the steering
control manifold to the steering pump flow compensator valve and high-pressure
cutoff valve.

Return oil from the HMU is directed to the steering filter (5) to the tank (6). Steering
pump case drain oil is directed to the case drain filter (11) to the tank. System
pressure can be checked using the pressure tap (3).

The secondary steering and brake retract motor (10) is electrically driven and is
controlled by a switch in the operator’s station. If the engine is OFF, the operator will
move this switch to release the parking brakes using the brake retract pump (7) or to
provide steering oil pressure using the secondary steering pump. Contained within
the secondary steering pump housing is the load sensing valve and relief valve (8).
The load sensing valve meters the proper amount of oil needed by the operator as the
steering demand changes and the relief valve provides backup pressure protection.

Caterpillar: Confidential Yellow

SERV1921 - 09/11 -9- Module 6 - Steering System

3
5
6
2

1
7
4

9_1

Steering control manifold The steering control manifold (1) is located behind the right strut on the right frame
components right strut rail. The disable valve and steering control valve have been combined into one valve
block assembly and the pressure reducing valve on the F-Series has been
eliminated.

Steering oil flows from the pump directly to the steering control manifold, through
the pump diverter valve (3), a load check valve (on the front of the manifold), and to
the hand metering unit. The steering pressure switch (2) monitors the output of the
steering pump. The steering pressure switch provides an input signal to the Chassis
ECM which sends a signal to the monitoring system to inform the operator of the
steering system condition. A steering system Level 1, 2, or 3 Warning is displayed if
the pressure is too low.

The primary relief valve (4) maintains the system pressure which is approximately
26000 kPa (3770 psi). The secondary relief valve (5) is set at approximately 20700
kPa (3002 psi) and is the back-up relief for the electric driven secondary steering
pump. Contained within the secondary steering pump housing, later in this module,
is another relief valve that is set lower to approximately 17585 kPa (2550 psi). This
relief valve works with the load sensing valve (inside the same housing) to maintain
the correct pressure and flow to the hand metering unit while the electric pump is
operating.

The primary relief valve inside the steering control manifold is a back-up relief valve
for the steering system. This relief valve is protects the steering system if the high
pressure cutoff valve on the steering pump malfunctions. Steering pressure is first
controlled by the high pressure cutoff valve.

Caterpillar: Confidential Yellow

SERV1921 - 09/11 -10- Module 6 - Steering System

Steering system pressures are measured on a pressure fitting underneath the cab.

The load signal diverter valve (6) and the shuttle valve (7) work with the disable
solenoid (not shown on this photo) to direct the load signal generated from the
steering pump controls to the hand metering unit.

When the machine lockout switch, located on the remote switch panel, is toggled,
a signal is sent to the Transmission/Chassis ECM. The Transmission/Chassis ECM
energizes the steering disable solenoid allowing service to safely be performed
behind the front wheels.

Caterpillar: Confidential Yellow

SERV1921 - 09/11 -11- Module 6 - Steering System

3
1

11_1

Steering control manifold This image shows the top of the steering control manifold. There are two load check
components behind right strut valves (1) in this system. One of them is located directly downstream of the pump oil
flow that travels through the pump diverter valve. The second is used with the oil flow
from the electric driven secondary steering pump.

When the steering disable solenoid valve (2) is energized, oil flow from the steering
pump to the HMU is blocked by the steering control manifold, which allows servicing
behind the front wheels with the machine running.

Pressure tap (3) is used to measure the load sensing pressure generated by the
steering system pump.

Caterpillar: Confidential Yellow

SERV1921 - 09/11 -12- Module 6 - Steering System

12_1
Steering system pressure tap This image shows the steering system pressure tap (arrow) located under the
operator’s station.

Caterpillar: Confidential Yellow

SERV1921 - 09/11 -13- Module 6 - Steering System

STEERING CONTROL MANIFOLD

(1) Pump Diverter Valve

(9) Secondary Relief Valve

(2) Pump Pressure Tap

(3) Check Valves

(8) Primary Relief Valve

(4) Disable Solenoid

(7) Shuttle Valve (5) Load Sensing

Pressure Tap

(6) Load Signal Diverter Valve

13_1
Steering control manifold This illustration shows the components of the steering control manifold.
components
• Pump diverter valve (1)

• Pump Pressure Tap (2)

• Two check valves (3)

• Disable solenoid (4)

• Load signal pressure tap (5)

• Load signal diverter valve (6)

• Shuttle valve (7)

• Primary relief valve (8)

• Secondary relief valve (9)

Caterpillar: Confidential Yellow

SERV1921 - 09/11 -14- Module 6 - Steering System

14_1

HMU This image shows the location of the HMU (arrow) for the 773G/775G. The HMU can
be accessed by removing a cover in front of the cab. The HMU is connected to the
steering wheel and controlled by the operator.

The HMU meters the amount of oil sent to the steering cylinders by the speed at
which the steering wheel is turned. The faster the HMU is turned, the higher the flow
sent to the steering cylinders, and the faster the wheels will change direction.

The steering system HMU is referred to as “Q-amp” which means flow amplification.
During a sudden steering change (steering wheel speed greater than 10 rpm),
additional steering pump oil flow will bypass the gerotor pump in the HMU and flow
directly to the steering cylinders. Steering oil flow to the cylinders is equal to the
gerotor pump oil flow plus the Q-amp bypass oil flow from the steering pump. The
steering oil flow is amplified up to 1.6:1. The purpose of the flow amplification is to
provide quick steering response when sudden steering changes are needed.

Two crossover relief valves are installed in the top of the HMU. The crossover relief
valves are installed in series with the left and right turn ports. If an outside force is
applied to the front wheels while the steering wheel is stationary, the crossover relief
valves provide circuit protection for the steering lines between the steering cylinders
and the HMU. The crossover relief valves allow oil to transfer from one end of the
steering cylinders to the opposite end of the cylinders.

Caterpillar: Confidential Yellow

SERV1921 - 09/11 -15- Module 6 - Steering System

To test the right crossover relief valve, install two tees with pressure ports in the
right turn steering hose at the steering cylinders. Steer the truck completely to the
right against the stops, and shut off the engine. An external pump supply must be
connected to one of the pressure ports on the right turn hose. Connect a pressure
gauge to the other pressure port on the right turn hose. Pressurize the steering
system, and the reading on the gauge will be the setting of the right crossover relief
valve.

To test the left crossover relief valve, install two tees with pressure ports in the left turn
steering hose at the steering cylinders. Steer the truck completely to the left against
the stops and shut off the engine. An external pump supply must be connected to
one of the pressure ports on the left turn hose. Connect a pressure gauge to the
other pressure port on the left turn hose. Pressurize the steering system, and the
reading on the gauge will be the setting of the left crossover relief valve.

Caterpillar: Confidential Yellow

SERV1921 - 09/11
Steering cylinder position sensor
on left steering cylinder
-16- Module 6 - Steering System
16_1
The steering cylinders are connected to the frame and the steering linkage.
The 773G/775G truck left steering cylinder is equipped with a position sensor located
below a cover (arrow) on the head end of the cylinder. The position sensor sends a
Pulse Width Modulated (PWM) signal to the Brake ECM indicating the cylinder piston
position within the piston stroke.
The Brake ECM uses the steering cylinder position to calculate the angle of the front
tires. The ECM uses the front tire angle information for the Traction Control System
(TCS) application.
The TCS monitors the ratio of the speed of each rear wheel in order to detect a
slippage in one of the wheels. When a slippage is detected for one of the rear
wheels, the secondary brakes will be applied to that wheel in order to apply torque to
the wheel with better traction. The position sensor is an important input to the TCS.
The cut-in wheel speed ratio of the TCS will vary with the steering angle of the truck.
That means that if the wheels are turned at a larger angle with respect to straight-line
motion, the cut-in ratio for the TCS to engage will increase.
Caterpillar: Confidential Yellow
SERV1921 - 09/11 -17- Module 6 - Steering System

In simple terms, when the truck is performing a tight turn, the ratio between the rear
wheels is expected to be larger and thus a larger cut-in ratio is required so that TCS
is not as sensitive while the machine is performing a tight circle. If the wheels are not
turned at all, the ratio of the wheel speed will be closer to one and the cut-in ratio of
the wheel speed is lower.

Caterpillar: Confidential Yellow

SERV1921 - 09/11 -18- Module 6 - Steering System

STEERING POSITION SENSOR

(4) (2)
Cylinder Sensor (3) (1)
Head End Head Magnet Rod

(5)
Connector
18_1

Steering cylinder position sensor
components
The steering cylinder position sensor uses a magnetorestrictive principle. A wire is
stretched inside the length of the sensor rod (1) to form a waveguide. At time zero, a
current pulse is transmitted down the wire by the electronics in the sensor
head (2). At the point where the pulse reaches the magnetic field of the
magnet (3), an acoustic pulse is generated and sent back to the sensor head.

Internal electronics convert the time zero to the time it takes the return pulse to reach
the sensor head into an electronic PM signal. The pulse width is directly proportional
to the position of the magnet. The sensor frequency is 500 Hz.

Caterpillar: Confidential Yellow

SERV1921 - 09/11 -19- Module 6 - Steering System

5
4
2

19_1

Brake, secondary steering pump, The secondary steering pump (1) and motor (2) on the 773G/775G are mounted to
and motor a bracket located on the front of the front frame crossmember. The bracket also
supports the brake oil cooler (3). The pump and motor assembly also includes the
brake retract pump section (4).

The secondary steering pressure switch (5) is also mounted next to the secondary
steering pump. The pressure switch detects if the wheels are being turned via the
steering wheel when secondary steering is activated. When the wheel is turned in
a secondary steering condition, the pressure switch will signal the Transmission/
Chassis ECM.

If the primary steering pressure sensor signals the Transmission/Chassis ECM that
the steering system pressure is low, the ECM will energize the secondary steering
relay located behind the cab. The secondary steering relay will then energize a
second larger relay located on the left frame, which will then energize the secondary
steering motor.

The primary relief valve for the secondary steering is accessible through a small
allen head plug (not visible) on the inboard side of the secondary steering pump. To
check the setting of the secondary steering primary relief valve, do not start the truck.
Turn ON the key start switch and depress the secondary steering switch in the cab.
Turn the steering wheel hard to the left or right while the secondary steering pump
is running. Secondary steering system pressures can be measured at the steering
system pressure port.

Caterpillar: Confidential Yellow

SERV1921 - 09/11 -20- Module 6 - Steering System

When the engine is started, the Chassis Electronic Control Module (Chassis ECM)
activates a relay that is located inside the cab, behind the trainer seat. The relay
activates a larger relay that is located on the inside of the left frame rail next to the
engine. Then, the larger relay activates brake release and secondary steering pump
(1). The brake release and secondary steering pump will operate for three seconds.
Secondary steering indicator (on the dash) will turn on when the pump is operating.

Caterpillar: Confidential Yellow

SERV1921 - 09/11 -21- Module 6 - Steering System

(1)
Steering
(14) Steering Cylinders
Cylinder Sensor

STEERING HYDRAULIC
SYSTEM (2)
HMU
HOLD
(13)
Crossover
Relief
Valves
(3)
Steering
Pressure
Sensor
(12) Steering Control Manifold

(15)
Pump Diverter (11) Resolver
Valve

(4)
(21) Load Load Signal
(24) Sensing Valve (10) Diverter Valve
Secondary Solenoid
Pressure
Switch M (17) (16)
Secondary Primary Steering (5) Flow Compensator
Steering Relief Valve
Relief Valve (6)
(23) (22) (20) (19)
High Pressure
Secondary Secondary Brake Secondary
Cutoff Valve
Steering Primary Steering Retract Steering
Relief Valve Pump Pump Motor
(7) Primary
Steering Pump

(25) Breather

(9) (8)
(18)
Case Drain Tank Level Sensors
Steering
Oil Filter Full
Filter
Fill
Low

21_1
STEERING SYSTEM OPERATION

Steering hydraulic system - LOW Shown is a schematic of the steering hydraulic system in the HOLD position. The
PRESSURE STANDBY primary steering pump (7) pulls oil from the steering tank. All piston-type pumps
produce a small amount of leakage to the case drain circuit for lubrication and
cooling. The case drain oil flows to the steering tank through a case drain
filter (9).

Steering oil flows from the pump to the steering control manifold (12). When the
steering disable valve solenoid (10) is de-energized, oil is allowed to flow to the
HMU (2).

The steering pressure sensor (3) monitors the output of the steering pump.

If the steering pressure sensor signals the Transmission/Chassis ECM that the
steering system pressure is low, the ECM will then energize the secondary steering
motor (19). Secondary steering supply oil will flow to the steering disable valve.

Two relief valves are installed in the steering valve. The secondary steering relief
valve (17) protects the secondary steering system if the secondary steering primary
relief valve (23) on the secondary steering pump malfunctions. The primary steering
relief valve (16) protects the primary steering system if the high pressure cutoff valve
(6) on the steering pump malfunctions.

Caterpillar: Confidential Yellow

SERV1921 - 09/11 -22- Module 6 - Steering System

Three check valves are located in the steering valve. Two check valves are used
to separate the primary and secondary steering systems. The third check valve
prevents oil from the return circuit from flowing into the steering control manifold.

Steering supply oil flows to the HMU from the steering control manifold. Return oil
from the HMU flows to the steering filter (18) to the steering tank.

The HMU meters the amount of oil sent to the steering cylinders (01) by the speed at
which the steering wheel is turned. The faster the HMU is turned, the higher the oil
flow sent to the steering cylinders, and the faster the wheels will change direction.

Two crossover relief valves (13) are installed in the top of the HMU. The crossover
relief valves are installed in series with the left and right turn ports. If an outside force
is applied to the front wheels while the steering wheel is stationary, the crossover
relief valves provide circuit protection for the steering lines between the steering
cylinders and the HMU. The crossover relief valves allow oil to transfer from one end
of the steering cylinders to the opposite end of the cylinders.

When the Transmission/Chassis ECM energizes the secondary steering motor

because the engine is stopped, load sensing signal oil will flow from the secondary
steering load sensing valve (21) through the load sensing resolver (11) to the HMU.
The load sensing valve uses the load sensing signal pressure to control the amount
of flow from the secondary steering pump (22) to the steering control manifold.
Secondary steering pressure is monitored by the secondary steering pressure switch
(24).

The 773G/775G Trucks use a dynamic load sensing steering system the same as
previous models. In a dynamic system, there is load sensing pressure and flow
between the HMU and the steering pump.

The resolver valve allows load sensing signal oil to flow between the HMU and the
primary steering pump or the secondary steering pump. In the NO STEER position,
oil flows to the HMU. In a LEFT or RIGHT STEER position, oil also flows from the
HMU to the resolver valve.

Normally, the secondary steering pump is OFF and the resolver is closed from the
HMU to the secondary steering pump. The flow from the primary steering pump
holds the resolver open and load sensing pilot signal pressure is present between
the HMU and the piston pump flow compensator (5).

The load sensing signal flow from the primary steering pump is also used for “thermal
bleed” through the HMU. The “thermal bleed” is used to keep the HMU temperature
the same as the rest of the steering system. Keeping the HMU the same temperature
prevents sticking.

Caterpillar: Confidential Yellow

SERV1921 - 09/11 -23- Module 6 - Steering System

(1)
Steering
(14) Steering Cylinders
Cylinder Sensor

STEERING HYDRAULIC
SYSTEM (2)
HMU
SECONDARY STEERING MOTOR ON
(13)
(ENGINE OFF) (RIGHT TURN) Crossover
Relief
Valves
(3)
Steering
Pressure
Sensor
(12) Steering Control Manifold

(15)
Pump Diverter (11) Resolver
Valve

(4)
(21) Load Load Signal
(24) Sensing Valve (10) Diverter Valve
Secondary Solenoid
Pressure
M (17) (16)
Switch
Secondary Primary Steering (5) Flow Compensator
Steering Relief Valve
Relief Valve (6)
(23) (22) (20) (19)
High Pressure
Secondary Secondary Brake Secondary
Cutoff Valve
Steering Primary Steering Retract Steering
Relief Valve Pump Pump Motor
(7) Primary
Steering Pump

(25) Breather

(9) (8)
(18) Tank Level Sensors
Case Drain
Steering
Oil Filter Full
Filter
Fill
Low

23_1
Steering hydraulic system - Shown is a schematic of the steering hydraulic system with the supplemental steering
SECONDARY STEERING MOTOR pump running with the engine OFF. When the engine stops or the operator engages
ON the top half of the brake release/secondary steering switch (with the engine OFF),
the supplemental steering pump (22) starts pumping oil through the load sensing
valve (21) to the steering control manifold (12) to provide oil for the HMU (2). The
load sensing valve uses the oil from the pump at each end of the load sensing valve
which constantly monitors how much oil the HMU needs (depending on how fast the
operator moves the steering wheel). Excess oil is directed to tank. If the pump
pressure exceeds approximately 17237 ± kPa (2500 ± 51 psi), the secondary
steering primary relief valve (23) will open and direct the oil to tank.

In this condition with the engine OFF, the operator rotates the steering wheel to the
left for a left turn, the steering envelope (5) (highlighted in yellow) in the HMU directs
the oil to gerotor which meters the oil to the steering cylinders for the left turn.

Caterpillar: Confidential Yellow