Ottawa Truck

Factory Service School

Hydraulic Training Class

 Hydraulic Plumbing

The Hydraulic system is an important part

of the Ottawa yard tractor. The ability to
operate with consistency, is what sets the
Ottawa apart.
 Introduction

The information in this section is meant to

provide the service technician with an
understanding of the Ottawa hydraulic
operations.
 Hydraulic System
The Ottawa System:
In covering this section the service technician
should gain a basic understanding of fluid
power principals and be able to locate, identify,
and understand the sub-systems and components
in those systems.
 Hydraulic System

The Ottawa System:

Uses a basic hydraulic system design to
develop and transfer fluid from the prime
hydraulic movers the pump, or control valve
to the cylinders.
 Hydraulic System
Hydraulic Power:

 Fluid under pressure is recognized as an

efficient, simple, and consistent method of
creating and delivering power to perform a
given task. The pump on an Ottawa in a normal
configuration is 10 G.P.M.
 Hydraulic System
Power
P.T.O. :
 The P.T.O. which connects to the hydraulic
pump helps serve this function.
 The P.T.O. and pump are connected to the
reservoir. They power the fifth wheel and other
components that are with-in the hydraulic system.
 Hydraulic System
How It Works
Hydraulic Flow:

 The Transmission powers the P.T.O.

 The P.T.O. powers the pump.
 The pump supplies the control valve.
 The valve supplies the cylinders.
 New Hydraulic System
Three Sub-Systems

 One 16 gallon reservoir directly supplies the

three sub-systems.
 The hydraulic pump is also a major link
between two of the three hydraulic systems.
 One fluid is used (Dexron 3).
 The Hydraulic System
The Ottawa Truck hydraulics system is
composed of three sub-systems:
1. Cab Tilt
2. Fifth Wheel/Boom Lift
3. Power Steering
 Hydraulic Power Tilt
Sub-System 1-

 Cab Tilt - Contains its own hydraulic pump,

valve, cylinder, and cab holdown. (Latch / UN
Latch).
•3 Shims
3,200 P.S.I.
 Hydraulic Power
Package
Cab Tilt

 Components -
 Motor control solenoid
 Tilt control switch
 Tilt cylinder
 Cab hold-down lock / Unlock
 Tilt Power System
Cab Tilt

 Internal Components-
 Solenoid operated two position valve
 Filter
 Pressure compensated restriction
 Check valve
 Hydraulic System
How it works
 Cab Tilt -
 To tilt the cab up the tilt control switch is
moved to the up position. An amp current
flows through the switch into the electric
motor. The motor then provides power to the
pump and fluid to the cylinder which raises
the cab. This motor is powered only in the
up position.
 Hydraulic System
How it works
 Cab Pump -
 The pump is normally producing in the
range of 3.25 - 3.5 G.P.M. flow when
moving the cab to the up position.
 Hydraulic System
How it works
 Cab Tilt -
 To lower the cab down you shift the switch to the
down position. Power is shifted to the solenoid of
the control valve. The valve shifts position and
directs the oil out from the cylinder base causing it
to retract and the cab to lower.
 Hydraulic System
How it works
 Cab hold-down-
 One hydraulic cylinder and one locking
mechanism are used to secure the cab in the down
position. The latching mechanism will receive
fluid from the pump and flow to the tilt cylinder.
The cylinder receives fluid simultaneously along
with the cab latch / UN-latch locking mechanism.
 Hydraulic System
How it works
 Cab hold-down-
 The latch cylinder requires less pressure to operate
and will open prior to the cab tilt. After the UN-
latch takes place the fluid continues to the tilt
cylinder and begins to raise the cab.
 Hydraulic Power
Package
Sub - System 2 -

 Fifth Wheel/Boom Lift - Contains its own

pump, valve, and cylinders.
 Hydraulic Power
Package
Sub - System

 Fifth Wheel/Boom Lift - The standard Ottawa

is semi-oscillating and stationary. It pivots in
one place only and movement is fore and aft.
This boom comes standard with a air operated
latch / UN-latch system.
 Hydraulic Power
Package
Fifth Wheel

 Components-
 Control lever (Cab)
 Two cylinders
 One control valve
 P.T.O. and Pump
 Lift Power System
Boom

 System Component-
 Mechanically operated two position self centering
lever that allows the operator to raise or lower the
boom without leaving the cab of the truck.
 Air activated latch and UN-latch lever located in
the fifth panel of the cab.
 Lift Power System
Boom

Component Operation-
 Hydraulic control valve that is self centering and
used to supply the hydraulics fluid for both the
fifth wheel and the cab tilt. This valve is located
just out from the left hand frame rail.
 Lift Power System
Boom

Internal Component-
 Pressure Settings which will determine the lifting
capabilities and the system safety features for the
boom.
 Hydraulic Capabilities
Cylinder capacity

 Boom -
 For Commando 30 series trucks with 4” cylinders
the maximum lift rate is 50,000 lbs.

 For Commando 50 and 60 series trucks with 5”

cylinders the maximum lift rate is 70,000 lbs.
 Hydraulic System
How it works

 Boom Lift -

 To raise the boom you push the cab boom lever to

the up position. The transmission supplies the
P.T.O. through the converter. The P.T.O. then sends
power to the pump which then supplies the valve.
The control valve sends fluid to the two cylinders
which begin to build pressure that slowly raises the
lift.
 Hydraulic System
How it works
 Boom Lift -
 When raising the boom you have the option of
limiting the length of the stroke. This is
accomplished by using a stroke reducer which is
installed on the cylinder, and around the shaft. The
height of the boom is then limited for the
appropriate applications. The following shows an
installation.
 Hydraulic System
How it works

 Boom Lift -
 To lower the boom simply push the lever to the
down position. The customer has two options
when ordering his boom lift. He can order the lift
with power up and power down. He can also order
it with power up and gravity down.
 There is an acceptable level of drop on a loaded
boom.
4” - 4.0” per hour
5” - 3.0” per hour
•Gauge Insert
 Hydraulic Power
Package
Sub - System 3
 Power Steering - Consists of two major
components within the system
 Pump (shared with the fifth wheel system)
 Steering Gear
 Control Valve
 Relief Valve
 Hydraulic Power
Package
Sub System 3 pre MD transmission
 Power Steering Pump- Contains its own
hydraulic control and relief valve.
– Open centered circuit, allows fluid to flow through the
valve.
– Return filter, located in the return line, filters oil for the
sub-systems.
 Hydraulic System
How it works
 Steering Pump-
 The pump is the heart of the steering system. It
converts the rotational energy supplied by the
engine into hydraulic energy, flow, and pressure,
for use by the steering gear. The flow rate on a
TAS 65 gear is going to be about 4.23 G.P.M.
 Hydraulic System
Theory
 Steering Pump-
 All pumps function by creating a partial vacuum
at the inlet, which causes pressure to force fluid
into the pump from the reservoir. The pump forces
the fluid into the system for use. The energized
fluid then powers the steering gear.
 Hydraulic System
Theory
 Steering Gear-
 The steering gear includes in its housing the
relief valve and the control valve. These functions
are performed internally in the gear housing rather
than externally like other hydraulic components.
 Steering System
Information
Pressure:
 The higher pressure a steering gear can withstand,
the more work it can perform. The max. pressure
for the Ottawa installed TAS gears is 1,875 psi.
The max. flow rate for all TAS gears is 8 gal/min.
 Hydraulic Steering
Settings

 Steering Parameters-
 The steering gear functions include setting the
parameters of the turning radius. This is done
automatically when the steering is first turned all
the way to the right and left directions. The
poppets set when the gear reaches the maximum
stroke in a given direction. These unloading valves
give steering pump protection.
 Hydraulic System
Information

 Energized Fluid-
 Can be thought of as having two major
components:
 Pump out-put flow relates to steering gear speed.
 The pump out-put pressure relates to steering gear force,
or work.
 Hydraulic System
Information

Energized Fluid:
 Flow can be thought of as the function of the pump.
When the pump is working properly there should be a
continuous fluid flow through the system.
 The hydraulic pump is located at the rear of the
engine. Connected to and directly behind the P.T.O.
Hydraulic Power System
Power:

 Is transmitted by fluid flowing under pressure

to the necessary systems.

 The Ottawa uses Dexron 3 Automatic

transmission fluid for its hydraulic systems.
 Hydraulic System
How It Works
Fluid:
 The amount of fluid flowing in the system
directly affects the work that the hydraulic
systems can do.
 Hydraulic System
Analyzing
Energized Fluid:
 Two major components:
Flow:
 Flowing oil causes motion. A control valve to the cylinder
directs pump flow. As the flowing oil starts to push against the
cylinder it meets resistance, this causes pressure to rise.
Pressure:
 The greater the resistance, the greater the pressure or
horsepower created.
 Hydraulic System
Basic Concepts
Pressure Is Equal To Force:
 If the circuit lacks power or lifting capabilities, then the
pressure is probably low. The hydraulic pump creates flow, not
pressure. It is the resistance to flow that creates pressure.
 Hydraulic System
Basic Concepts
Pressure Is Equal To Force:
 Think of resistance as load. The pressure will rise to meet the
load. The pressure on an unloaded fifth wheel will be very
low, a loaded fifth wheel will be very high. This is referred to
as working pressure or pressure required to complete the job.
 Hydraulic System
Basic Concepts
Flow Is Equal To Speed:
 If cylinders lack speed, the flow is probably the problem. The
function of the pump is to create flow, and it’s the resistance
to that flow that creates pressure.
 Hydraulic Maintenance
Fluid :
 Fluid levels ?

 Burnt or degraded oil

 Entrapped air
 Hydraulic System
Component Problems
One sub-system in an Ottawa can effect
another in a negative way by causing hydraulic
fluid contamination. It is important to check the
fluids at regular intervals. It is critical to
maintain the maintenance schedule that Ottawa
recommends.
 Hydraulic System
Component Problems
Excessive Heat:
 Created by but not limited to internal leakage at
the relief valve, and worn hydraulic pumps.
 Hydraulic System
Component Problems
Air Contamination:
 Loose fittings and worn seals can cause air to
enter the system. The P.D.I. requires checking for
loose fittings upon delivery.
 Hydraulic System
Basic Concepts
Remember two things when troubleshooting:

1. Pressure is equal to force.

2. Flow is equal to speed.
 Hydraulic System
Troubleshooting

Problem Identification:
 A visual inspection.
 Hydraulic System
Troubleshooting
Systems Analyzer:
 Consists of a flow reading tube, pressure gauge, and a load valve.
 Hydraulic System
Troubleshooting
Problem Identification:
 It can be difficult to identify the particular part in a hydraulic
system that is not working properly, unless you take a step by
step measurement of the flow, pressure, and temperature of
fluid at given points in the system.
 Hydraulic System
Failure
When a hydraulic power system is not operating
properly, the trouble is usually traced to:
 The pump may have worn parts.
 A worn or improperly set spring.
 The fluid may be leaking at the control valve.
 The fluid may be leaking past the
cylinder seals.
 Hydraulic System
Troubleshooting
 Oil flow can be measured under load or with no load.
 To load the system, the load valve is slowly closed and pressure
rises in the system.
 As the pressure rises, the internal leakage in the system should
become more apparent.
 Step by step placement of the analyzer in the hydraulic system
will provide the information needed to isolate the problem at
the component level.
 Hydraulic schematics should be used to assist the technician in
isolating the problem.