Sie sind auf Seite 1von 17

Service Training MALAGA

777D Off Highway Truck


STEERING SYSTEM
HOLD
ELECTRONIC CONTROL MODULE STEERING HYDRAULIC TANK HAND METERING UNIT (HMU)

CROSSOVER RELIEF VALVES

OIL FILTER MAGNETIC SWITCH

MAIN RELIEF CHECK VALVE

SECONDARY STEERING PUMP

CHECK VALVE

FLOW SWITCH ACCUMULATOR STEERING PUMP FLOW CONTROL VALVE STEERING CYLINDERS

VII STEERING.
1. 2. 3. 4. Components Layout Operation Maintenance Testing & Adjusting

777D Off Highway Truck


CHAPTER : STEERING

TYPICAL OFF-HIGHWAY TRUCK STEERING COMPONENT LOCATIONS


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

HMU

STEERING ECM OIL FILTER ACUMULATOR

HOIST PUMP

HMU

CROSSOVER RELIEF VALVES

STEERING PUMP

Page:

VI-1

Page: VI-2

STEERING SYSTEM
HOLD

HAND METERING UNIT (HMU) ELECTRONIC CONTROL MODULE

CROSSOVER RELIEF VALVES

STEERING HYDRAULIC TANK

OIL FILTER MAGNETIC SWITCH

CHAPTER : STEERING

MAIN RELIEF CHECK VALVE

777D Off Highway Truck

SECONDARY STEERING PUMP FLOW SWITCH

CHECK VALVE

ACCUMULATOR STEERING PUMP FLOW CONTROL VALVE STEERING CYLINDERS

Page: VI-3

STEERING SYSTEM
RIGHT TURN

HAND METERING UNIT (HMU) ELECTRONIC CONTROL MODULE

CROSSOVER RELIEF VALVES

STEERING HYDRAULIC TANK

OIL FILTER

CHAPTER : STEERING

MAGNETIC SWITCH

777D Off Highway Truck

SECONDARY STEERING PUMP

STEERING PUMP

ACCUMULATOR FLOW CONTROL VALVE STEERING CYLINDERS

777D Off Highway Truck


CHAPTER : STEERING

STEERING FLOW CONTROL VALVE


TO HMU

MAIN RELIEF VALVE FROM HMU

CHECK VALVE

FLOW CONTROL ORIFICE

TO TANK CHECK VALVE FROM SECONDARY STEERING PUMP FROM PUMP

CHECK VALVE

SIGNAL TO SECONDARY STEERING

FLOW SWITCH CLOSED

Page:

VI-4

Page: VI-5

HAND METERING UNIT HOLD

INPUT SHAFT

BALL IN HELICAL GROOVE

STATIONARY GEAR

COMMUTATOR

CHAPTER : STEERING

777D Off Highway Truck

TORSION BAR VALVE SPOOL TO TO TO TANK CYLINDER CYLINDER ROTATING GEAR DRIVE LINK

FROM PUMP

Page:

HAND METERING UNIT


LEFT TURN

VI-6

COMMUTATOR STATIONARY GEAR BALL INPUT SHAFT CHAPTER : STEERING

777D Off Highway Truck

TORSION BAR TO TANK FROM TO PUMP CYLINDER ROTATING GEAR DRIVE LINK

VALVE SPOOL

FROM CYLINDER

Page: VI-7

HAND METERING UNIT


RIGHT TURN STATIONARY GEAR COMMUTATOR INPUT SHAFT BALL

CHAPTER : STEERING

777D Off Highway Truck

TORSION BAR FROM CYLINDER TO TANK TO CYLINDER FROM PUMP

VALVE SPOOL

ROTATING GEAR

DRIVE LINK

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

PRESSURE TESTS TEST 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 SPECIFICATIONS ACTUAL

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 METERING UNIT (HMU) CROSSOVER RELIEF VALVES

STEERING HYDRAULIC TANK OIL FILTER

STEERING CYLINDERS SECONDARY STEERING PUMP

ACCUMULATOR FLOW CONTROL VALVE

STEERING PUMP

HAND METERING UNIT (HMU)

CROSSOVER 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 _______________ Air/Water in Oil ?_______ Suction Screen Debris ? _______ Oil leaks ? ______________ Oil Filter Examination ______

PRESSURE TESTS TEST 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 SPECIFICATIONS ACTUAL

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

777D Off Highway Truck


CHAPTER : STEERING

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

A I

E D

H K G

Flow Control Valve Oil Filter Crossover Relief Valves Secondary Steering Pump Steering Hydraulic Tank Automatic/Manual Panel Switch

Hand Metering Unit Steering Pump Steering Cylinders Accumulator Magnetic 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 To Hand Metering Unit Relief Valve Secondary Steering Pump Inlet From Hand Metering Unit Steering Pump Inlet Flow Control Orifice To Steering Hydraulic Tank

E G F
Page: VI-16