Global Manpower Development

777G Off-Highway Truck

Steering System
Module 6 - Text Reference

SERV1934

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SERV1934 - 12/11 -2- Module 6 - Steering System

LEARNING OUTCOMES
Participants will meet the following learning outcomes during the presentations,
lab exercises, and post-assessment of this Steering System module for the
777G Off-Highway Truck:

• Given a visual presentation in the classroom of the 777G Off-Highway Truck steering
system, the participant will take notes on the identification, location, and functionality of
the major components of the steering system.
• Given a 777G Off-Highway Truck and the Lab 1 Worksheets, the participant will locate
and identify the steering system components during a lab exercise.
• Given a 777G Off-Highway Truck, appropriate tooling and service information, the
participant will perform hydraulic system tests on the steering system during a lab
exercise.
• Given a multiple choice test on the steering system, the participant will identify the
correct answers during a post-assessment.

Pre-module Learning Outcomes
(objectives):
• This slide and statement for
the 777G Steering System
module should be shown at the
beginning of the module.
Participants will meet the following learning outcomes during the presentations, lab
exercises, and post-assessment of this Steering System module for the 777G
Off-Highway Truck:
• Given a visual presentation in the classroom of the 777G Off-Highway
Truck steering system, the participant will take notes on the
identification, location, and functionality of the major components of the
steering system.

• Given a 777G Off-Highway Truck and the Lab 1 Worksheets, the

participant will locate and identify the steering system components
during a lab exercise.

• Given a 777G Off-Highway Truck, appropriate tooling and service

information, the participant will perform hydraulic system tests on the
steering system during a lab exercise.

• Given a multiple choice test on the steering system, the participant will
identify the correct answers during a post-assessment.

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SERV1934 - 12/11 -3- Module 6 - Steering System

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INTRODUCTION

• Identify the major steering The steering system on the 777G is similar to the 777F except the steering disable
system components valve has been combined with the steering control valve into one valve block
assembly.

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 disable valve and steering control valve (2)
• HMU (3)
• Steering tank (4)
• Secondary steering motor and pump (5)
• Steering cylinders (6)

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STEERING SYSTEM COMPONENTS

• Identify the steering system The steering system tank is located on the right platform.
components on the right platform
Check the steering system oil level at the sight gauge (1).

The steering system return oil filter (2), the steering case drain oil filter (3), and the
brake charging oil filter (4) are located inside the filter compartment (5) on the outside
of the right frame rail.

Case drain oil from the steering pump returns to the hydraulic tank through the case
drain filter.

Before removing the steering system oil cap (6) to add oil to the steering system,
depress the pressure release button (7) on the breather to release any remaining
pressure from the tank.

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

Also mounted to the steering tank are the hoist and brake cooling hydraulic tank
breather (8) and the torque converter and transmission breather (9).

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SERV1934 - 12/11 -5- Module 6 - Steering System

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• Identify the steering oil level The steering oil level is monitored by the Transmission/Chassis ECM via three
sensors 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)

• ADD (2)

• FULL (3)

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SERV1934 - 12/11 -6- Module 6 - Steering System

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• Identify the steering system
components
The 777G 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.

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.

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SERV1934 - 12/11 -7- Module 6 - Steering System

Load Sensing
Pressure
To Steering
Valve
STEERING PUMP
from HMU (8) and HMU (7) LOW PRESSURE STANBY

High Pressure
Cutoff Valve (6) Actuator Piston (4)

Flow
Compensator (1)

Load Sensing
Controller (2)
Swashplate
Piston (3)

Case
Drain Filter (5)

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• Explain the operation of the When the truck is traveling in a straight path, the steering cylinders require virtually
steering pump during LOW no flow or pressure. The HMU provides a very low pressure load sensing signal to
PRESSURE STANDBY 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.

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SERV1934 - 12/11 -8- Module 6 - Steering System

Load Sensing
Pressure
To Steering
Valve
STEERING PUMP
from HMU (8) and HMU (7) MAXIMUM FLOW
High Pressure
Cutoff Valve (6)
Actuator Piston (4)

Flow
Compensator (1)

Load Sensing
Controller (2)

Swashplate
Piston (3)
Case
Drain Filter (5)

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• Explain the operation of the
steering pump during 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.

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SERV1934 - 12/11 -9- Module 6 - Steering System

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• Identify the disable valve and The steering disable valve (1) is located behind the right strut on the right frame rail.
pressure ports The disable valve and steering control valve have been combined into one valve
block assembly. This image shows the rear of the disable valve.

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

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.

Also located on the steering disable valve is a pressure port (3) for checking the load
sensing signal to the pump.

Steering system pressure can be checked at the steering system pressure port (4)
on the pump supply line.

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SERV1934 - 12/11 -10- Module 6 - Steering System

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• Identify the steering disable valve
components
This image shows the front of the disable valve. Steering oil flows from the pump
through the steering disable valve to the HMU located at the base of the steering
column. The primary steering pressure sensor (1) monitors the output of the steering
pump. The steering pressure sensor provides input signals to the Transmission/
Chassis ECM, which sends a signal to the monitoring system to inform the operator
of the steering system condition. A steering system warning is displayed if the
pressure is too low.

Two relief valves are located on the steering disable valve. The secondary steering
back-up relief valve (2) protects the secondary steering system if the relief valve
on the secondary steering pump malfunctions. The primary steering back-up relief
valve (3) protects the primary steering system if the high pressure cutoff valve on the
steering pump malfunctions. Primary steering pressure is first controlled by the high
pressure cutoff valve located on the steering pump.

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SERV1934 - 12/11 -11- Module 6 - Steering System

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• Identify the HMU This image shows the location of the HMU (arrow) for the 777G. 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.

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SERV1934 - 12/11 -12- 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; 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, the reading
on the gauge will be the setting of the left crossover relief valve.

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SERV1934 - 12/11
• Identify the steering cylinder
position sensor on the left
steering cylinder
-13- Module 6 - Steering System
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The steering cylinders are connected to the frame and the steering linkage.
The 777G 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.
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SERV1934 - 12/11 -14- Module 6 - Steering System

STEERING POSITION SENSOR

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

Connector
(5)
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• Identify the 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.

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SERV1934 - 12/11 -15- Module 6 - Steering System

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• Identify the steering system The secondary steering pump (1) and motor (2) on the 777G are mounted to a
components on the front frame bracket located on the front of the front frame crossmember. The bracket also
crossmember 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.

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SERV1934 - 12/11 -16- Module 6 - Steering System
Steering
Cylinders
Steering (13)
Cylinder Sensor (22)

STEERING HYDRAULIC
SYSTEM HMU
(5)
LOW PRESSURE STANDBY
Crossover
Relief
Valves
(14) Steering
Pressure
Sensor
(6)
Steering Disable Valve (3)

Resolver (16)

Load
Solenoid
Secondary Sensing Valve
(4)
Pressure (15)
Switch
M Primary Steering
(18) Secondary
Steering Back-up Flow Compensator (19)
Back-up Relief Valve
Relief Valve (10) High Pressure
Secondary Secondary Brake Secondary
(8) Cutoff Valve
Steering Primary Steering Retract Steering
(11)
Relief Valve Pump Pump Motor
(9) (17) (20) (7)
Primary
Steering Pump
(1)

Case Drain Tank Level Sensors

Steering
Oil Filter (21)
Filter
(2)
(12)

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STEERING SYSTEM OPERATION

• Explain the operation of the
steering hydraulic system during
LOW PRESSURE STANDBY
Shown is a schematic of the steering hydraulic system in the HOLD position. The
primary steering pump (1) 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 (2).

Steering oil flows from the pump to the steering disable valve (3). When the steering
disable valve solenoid (4) is de-energized, oil is allowed to flow to the HMU (5).

The steering pressure sensor (6) 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 (7). Secondary steering supply oil will flow to the steering disable valve.

Two relief valves are installed in the steering valve. The secondary steering back-
up relief valve (8) protects the secondary steering system if the secondary steering
primary relief valve (9) on the secondary steering pump malfunctions. The primary
steering back-up relief valve (10) protects the primary steering system if the high
pressure cutoff valve (11) on the steering pump malfunctions.

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SERV1934 - 12/11 -17- 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 disable valve.

Steering supply oil flows to the HMU from the steering valve. Return oil from the
HMU flows through the steering valve and the steering filter (12) to the steering
tank.

The HMU meters the amount of oil sent to the steering cylinders (13) 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 (14) 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,

load sensing signal oil will flow from the secondary steering load sensing valve (15)
through the load sensing resolver (16) to the HMU. The load sensing valve uses
the load sensing signal pressure to control the amount of flow from the secondary
steering pump (17) to the steering disable valve. Secondary steering pressure is
monitored by the secondary steering pressure switch (18).

The 777G 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 (19).

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.

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SERV1934 - 12/11 -18- Module 6 - Steering System

LEARNING OUTCOMES
Participants have met the following learning outcomes during the presentations,
lab exercises, and post-assessment of this Steering System module for the
777G Off-Highway Truck:

• Given a visual presentation in the classroom of the 777G Off-Highway Truck steering
system, the participant took notes on the identification, location, and functionality of the
major components of the steering system.
• Given a 777G Off-Highway Truck and the Lab 1 Worksheets, the participant located and
identified the steering system components during a lab exercise.
• Given a 777G Off-Highway Truck, appropriate tooling and service information, the
participant performed hydraulic system tests on the steering system during a lab
exercise.
• Given a multiple choice test on the steering system, the participant identified the correct
answers during a post-assessment.

Post-module Learning Outcomes
(objectives):
• This slide and statement for
the 777G Steering System
module should be shown at
the end of the lab exercise
and post-assessment.
Participants have met the following learning outcomes during the presentations, lab
exercises, and post-assessment of this Steering System module for the 777G
Off-Highway Truck:
• Given a visual presentation in the classroom of the 777G Off-Highway
Truck steering system, the participant took notes on the identification,
location, and functionality of the major components of the steering
system.

• Given a 777G Off-Highway Truck and the Lab 1 Worksheets, the

participant located and identified the steering system components
during a lab exercise.

• Given a 777G Off-Highway Truck, appropriate tooling and service

information, the participant performed hydraulic system tests on the
steering system during a lab exercise.

• Given a multiple choice test on the steering system, the participant

identified the correct answers during a post-assessment.

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