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2621 South Daimler St.Santa Ana, CA. 92705Tel. 949.752.8818 Fax 949.756.1520www.ktihydraulicsinc.comDC PowerUnit TroubleShootingGuide1

2621 South Daimler St.Santa Ana, CA. 92705Tel. 949.752.8818 Fax 949.756.1520www.ktihydraulicsinc.comDC Power UnitTrouble Shooting GuideThe purpose of this guide is to help you trouble shoot KTI DC Hydraulic PowerUnits, by explaining how the electric & hydraulic circuits work together to perform eachfunction. Also included are some tricks & tips we have found talking to you thecustomer.This guide will help you fix the majority of problems you face in the field. If yourun into an issue not explained please let us know, our service staff will be more thanwilling to help solve your issueWarrantyKTI Hydraulics Inc, Warranties its products free from defects in material, workmanship &design for a period of 2 years from the date of manufacture on DC Units & 1 year fromdate of manufacture on AC Units. Under no circumstances is there warranty of fitnessfor a particular use and KTI Hydraulics Inc. cannot and does not accept responsibilities ofany of its products that have subject to improper installation, improper application,negligence tampering or abuse. All repairs must be authorized by factory to reduce therisk of voiding warranty. KTI Hydraulics liability warranty shall extend only to correctionF.O.B KTI Hydraulics Inc. We make no other warranties expressed or implied and are notresponsible for any damage resulting from use by any buyer or user, our liability beinglimited to the value of the product sold, or obligated to repair or replace defective part.For warranty information or warranty request please contact Customer Service.Power Units without Model Number & Serial Number will not be covered underwarranty, when calling please have model number & Serial Number ready. Anyinformation & symptoms of issue will help us with your issue.2

2621 South Daimler St.Santa Ana, CA. 92705Tel. 949.752.8818 Fax 949.756.1520www.ktihydraulicsinc.comNot Covered Under WarrantyKTI Hydraulics cannot and does not accept responsibilities of any type or any of its products that havebeen subjected to improper installation, improper application, negligence, tampering or abuse.The Following are reasons why KTI does not cover under warranty:1.) Improper Installation- Such as over torque of mounting bolts during installs resulting in damageto Power Unit. KTI cannot and does not accept responsibilities for damage to its product undersuch circumstances.2.) Improper Application- KTI cannot and does not accept responsibility for any units that have beenimproperly spec out due to lack of information about that particular application. Example; if anapplication requires water sealed motor and it is not specified about to what elements unit willbe exposed to. KTI cannot and does not accept responsibilities for motor failure due to corrosionor rust. KTI relies on customer to provide all information relating to the application such as itsexposure or enclosure as to where unit will be mounted.3.) Negligence- KTI will not take responsibility for any product neglected by customer. Such ascustomer leaves box to trailer open and unit gets wet resulting in failure of motor or valves dueto the corrosion or rust, Customer neglected to service on unit resulting in sever contaminationto unit.4.) Tampering- Units tampered with and or revised other than factory assessment will not beconsidered for warranty. All relief valves are factory pre-set. Any adjusting or tampering canresult in severe injury or even death. Units adjusted in field can result in burning up of solenoids,motors and coils in which KTI does not take responsibility for. Any adjustments in field must beapproved by KTI via written email / Fax.5.) Abuse- KTI stands behind their products one hundred percent. All products are tested beforeshipping. Any abuse to products will not be considered for warranty. The following areconsidered abuse per KTI. Low Voltage / battery- Causes high amp draw. High amps can burn up electricalcomponents such as start solenoids, coils, motors, and contacts in hand controls.Contamination – Contamination in the system can cause valve failure and pump failure.It can also lead to cylinder failure as well.Rust – Water in fluid can cause valves to rust resulting in failure such as hanging up ofvalve spool, corrosion and seizure of pump, and/or motor.Improper Fluid – Can cause failure of pump and motor. The wrong viscosity grade cancause pump to struggle resulting in bogging down of motor which can result in highamp draw of unit. High Amp draw can result in burning up of Motor and othercomponents.3

2621 South Daimler St.Santa Ana, CA. 92705Tel. 949.752.8818 Fax 949.756.1520www.ktihydraulicsinc.comWarningWhen working on a Hydraulic System Always Insure Hydraulic Lines havebeen depressurized. Hydraulic Injection can cause loss of fingers & evenloss of Life in severe cases.Hydraulic Injection can seem like a Bee Sting. If you are ever bitten byHydraulic Injection go directly to the Emergency Room for Treatment.For more information on Hydraulic Injection contact:Fluid Power Training Institutewww.fpti.orgIntroduction to Troubleshooting Hydraulic Power UnitsWhen troubleshooting Hydraulic Power Units you first want to understand howthe hydraulic circuit works with the electrical circuit, Also the sequence of operation foreach hydraulic circuit. If you can understand these two things you can fix most hydraulicsystems.Most problems with mobile Hydraulic Power Units are electrical, the mostcommon being poor ground condition which will simulate low battery. Always insureyour battery is getting charged. If you are using your hydraulic system frequently youmay need to place the battery on charge more frequently.Never adjust relief valves unless consulting factory. Relief valves are factorypreset to the manufacturer’s specification. Adjusting the relief valve will not help thepower unit build pressure. The last thing you want to do is adjust the relief valve.Tampering with relief valve could cause injury, catastrophic failure resulting in death.Having a designated auxiliary battery for your hydraulic system is recommended.Always place a fuse or circuit breaker in charge wire to auxiliary battery. If your batterygets low the Fuse or circuit breaker will blow, if this happens reference battery sectionin Guide (Page 8).After you have ruled out the electrical circuit use the Quick Reference Chart tosolve your issue. Having a 5000 psi Pressure Gage, Flow Meter & Extra Fitting to Tee inthe Pressure Gages will make your job a lot easier.4

2621 South Daimler St.Santa Ana, CA. 92705Tel. 949.752.8818 Fax 949.756.1520www.ktihydraulicsinc.comPower Up Gravity Down(Circuit 103)General Operation InstructionsExtending Cylinder1. Pressing UP Button on Yellow Hand Control (not shown) Provides Battery Power toStart Solenoid & DC MotorA. When Start Solenoid (not shown) is activated power is provided to DC Motor(1245-15) which turns gear pump (PL-2.10) to build pressure.B. Fluid travels through the Check Valve (LCV-08-P-0.3) & out the “P” Port toextend the cylinder.C. When cylinder reaches the end of its stroke or maximum load fluid willbypass to tank. Primary Relief Valve set @ 3200 PSI. Relief Valve is FactoryPreset, Tampering With Safety Wire Voids Warranty and could result inSerious Injury or Even Death.5

2621 South Daimler St.Santa Ana, CA. 92705Tel. 949.752.8818 Fax 949.756.1520www.ktihydraulicsinc.comRetracting Cylinder2. Pressing Down Button on Yellow Hand Control (not shown) Provides Power to Coilon Solenoid Valve (LSV-08-2NCP).A. Activating Solenoid Opens Normally Closed 2-way Valve Allowing Fluid toreturn to tank.B. (Optional) When Fluid is returning to tank Flow Control may be placed inmanifold controlling the speed of the cylinder retracting.6

2621 South Daimler St.Santa Ana, CA. 92705Tel. 949.752.8818 Fax GREEN"UP" BLUE WIRE or RedGRAY"DOWN" GREEN WIRETO GROUNDGRAY""COMMON"' WHITETO BATTERYMOTOR TERMINALGROUND(SQUARE)DOWNNC2W COILBLUESingle Acting Wiring Diagram7

2621 South Daimler St.Santa Ana, CA. 92705Tel. 949.752.8818 Fax 949.756.1520www.ktihydraulicsinc.comPower Up Power Down(Circuit 111)General Operation InstructionsExtending Cylinder3. Pressing UP Button on Yellow Hand Control (not shown) Provides Battery Power toStart Solenoid, DC Motor & Cylindrical Coil at the Same Time.A. When Start Solenoid (not shown) is activated power is provided to DC Motor(1245-15) which turns gear pump (PL-2.10) to build pressure.B. When Cylindrical Coil (On LSV2-08-4CO) is activated, the Directional ControlValve (LSV2-08-4CO) shifts allowing fluid to travel through the NormallyClosed 2-Way section of the Load Holding Valve (LSPC-08-4-00) & out Port Aof Manifold which will extend cylinder.C. When the gear pump (PL-2.10) is building pressure to extend the cylinder thePilot Operated section of Lowering Valve (LSPC-08-4-00) is piloted open toallow fluid from rod end of cylinder to travel back to tank. Pilot Ratio forlowering Valve is 2.5/1D. When cylinder reaches the end of its stroke or maximum load fluid willbypass to tank. Primary Relief Valve set @ 3200 PSI. Relief Valve is FactoryPreset, Tampering With Safety Wire Voids Warranty and could result inSerious Injury or Even Death.Retracting Cylinder4. Pressing Down Button on Yellow Hand Control (not shown) Provides Power to StartSolenoid, DC Motor & Square Coil (on LSPC-08-4-00).A. When Start Solenoid (not shown) is activated power is provided to DC Motor(1245-15) which turns gear pump (PL-2.10) to build pressure.B. Pressure flows through Directional Control Valve (On LSV2-08-4CO) thenthrough the Lower Section of Load Holding Valve (LSPC-08-4-00) out Port B ofManifold Retracting cylinder.C. When the Square Coil (on LSPC-08-4-00 is Energized Opening the NormallyClosed 2-Way Section of the Lowering Valve (LSPC-08-4-00) allowing fluid toreturn through Directional Control Valve (LSV2-08-4CO) & back to tank.8

2621 South Daimler St.Santa Ana, CA. 92705Tel. 949.752.8818 Fax 949.756.1520www.ktihydraulicsinc.comD. When cylinder reaches the end of its stroke fluid bypasses to tank via 2 ndrelief valve (RVSAE6-30) set @ 1500 psi. 2nd relief valve is in place to preventover pressurization of rod end of cylinder & thermal expansion.Extending CylinderOrange is Fluid Traveling from the Gear Pump to the Bore of the Cylinder.Green is the Fluid Returning from the Rod End of the cylinder back to the Reservoir.9

2621 South Daimler St.Santa Ana, CA. 92705Tel. 949.752.8818 Fax 949.756.1520www.ktihydraulicsinc.comRetracting the CylinderOrange is Fluid Traveling from the Gear Pump to the Rod End of the Cylinder.Green is the Fluid Returning from the Bore of the Cylinder back to the Reservoir.10

2621 South Daimler St.Santa Ana, CA. 92705Tel. 949.752.8818 Fax 949.756.1520www.ktihydraulicsinc.comDouble Acting Wiring Diagram"UP" BLUE or RED WIRE"DOWN" GREEN WIRETO BATTERYMOTOR TERMINAL11DNUPREMOTE395-17GREENGRAYTO LUE or REDNC2W COILUPDOWN4 WAY COIL""COMMON"' WHITE

2621 South Daimler St.Santa Ana, CA. 92705Tel. 949.752.8818 Fax 949.756.1520www.ktihydraulicsinc.comLow Voltage & Battery IssuesLow Voltage causes high amp draw which equals increased heat & reduced rpm of DCMotor. Many times low voltage will actually be poor ground condition. Low voltage willcause carbon buildup on contacts of start solenoid, coils on directional valve to fail &melt the resin on the field windings of dc motor (you will smell it & see the smoke whenthis happens).Low Voltage can be caused by improper sized wire, poor connections, corrosion,auxiliary battery not being charged or possible blown fuse on charge wire.Trick: By attaching one end of jumper cables to the negative side of the battery & theother to the aluminum manifold, you can improve the ground condition. This is a fastway to check for poor groundBattery Cable Selection GuideAmps 5 Ft.5-10 Ft.10-15 Ft.15-20 Ft.20-25 Ft.25-30 Ft.100-1504 Gauge2 Gauge0 Gauge02 Gauge02 Gauge03 Gauge150-1904 Gauge1 Gauge02 Gauge03 Gauge04 Gauge04 Gauge190-2502 Gauge0 Gauge02 Gauge04 Gauge04 Gauge04 Gauge250-3000 Gauge02 Gauge03 Gauge04 Gauge04 Gauge04 Gauge12

2621 South Daimler St.Santa Ana, CA. 92705Tel. 949.752.8818 Fax 949.756.1520www.ktihydraulicsinc.comRelief ValvePrimary Relief ValveSecondary Relief Valve(Sometimes used as Primary)Relief valves primary function is to prevent over pressurization of hydraulicsystem. On a double acting circuit a second relief valve will be placed after the checkvalve to prevent thermal expansion & over pressurization of cylinder. This could result incatastrophic failure.Common Problems with Relief Valves Debris stuck on valve seat causing relief valve not to build maximum systempressureAdjustment screw being screwed in all the way causing the spring to compress &crack early or not be able to be readjusted to specified pressure setting. (mostrelief valves will start to crack 100-300 psi before full bypass)Torn or extruded O-rings13

2621 South Daimler St.Santa Ana, CA. 92705Tel. 949.752.8818 Fax 949.756.1520www.ktihydraulicsinc.comCheck ValveA check valve is similar to a relief valve but has a lighter spring allowing the fluidto pass through it with little pressure loss. The purpose for this relief valve in thehydraulic circuits covered in this guide is to prevent the fluid from back flowing to thepump.Common Problems with Check Valves Debris stuck on valve seatTorn or extruded O-ringsSilting – Debris buildup in valve causing poppet not to move freely14

2621 South Daimler St.Santa Ana, CA. 92705Tel. 949.752.8818 Fax 949.756.1520www.ktihydraulicsinc.comNormally Closed 2-WayA Normally Closed 2-Way is nothing more than a solenoid operated check valve.When the Solenoid (coil) is activated the pilot pin retracts allowing the pressure toequalize on either side of the poppet then the poppet will retract.Common Problems with Normally Closed 2-Way Debris stuck on valve seatTorn O-rings on noseSilting – Debris buildup in valve causing poppet not to move freelyBent Stem on valve (Stem is the portion of the valve the coil slides over)15

2621 South Daimler St.Santa Ana, CA. 92705Tel. 949.752.8818 Fax 949.756.1520www.ktihydraulicsinc.comDirectional Control ValveDirectional Control Valves simply tell the hydraulic fluid where to go. Byactivating the Solenoid (coil) the spool will shift changing the flow path.The tolerances between the spool & the cage are tight & overtime thesetolerances can increase causing the valve to have excessive leakage. You might noticethis if over time, the cycle times have been increasing where eventually you won’t beable to lift a load.16

2621 South Daimler St.Santa Ana, CA. 92705Tel. 949.752.8818 Fax 949.756.1520www.ktihydraulicsinc.comMost common reasons for the directional control valve is not functioning Electromagnetic coil not activatingOver torqued valve (18ft-lbs. Max)Torn or extruded O-ringsDebris stuck in valveRust inside valve preventing spool from shiftingBent Stem on valve (Stem is the portion of the valve the coil slides over)Below is the most common directional valve used 4-way 2 position criss-crossWays to Check Directional Control Valve Valve not shiftinga. Ensure valve is not bent (stem is the section of valve the coil slides over)b. Remove valve from manifoldc. Use dipstick on breather to push in section 1 on nose of valve. This willmanually shift the valve.d. If you can’t shift the valve check for debris & or replaceTrick: By removing the white wire from the start solenoid you can place the coil back on the valve& shift the valve after it has been removed from the manifold.The valve should shift just as fast as you press the button if you see the valve hesitate toshift clean valve & try again. If problem persists replace valve Valve stuck in activated positiona. After removing valve check spool to see if it is covering the bottom half ofthe crossed drilled holes in section 2 of valveb. In the valves spring offset position valve should cover the bottom half of thecrossed drilled holes on section 2 & 417

2621 South Daimler St.Santa Ana, CA. 92705Tel. 949.752.8818 Fax 949.756.1520www.ktihydraulicsinc.comLoad Holding ValveThe load holding valve checks both rod & bore end of cylinder, this valve isdifferent than any other load holding valve. The solenoid (coil) operated portion allowsyou to retract the cylinder without having to add an orifice to restrict the flow of fluiddown like you would with a dual pilot operated check valve.Common Issues with Load Holding Valve Debris in check valvesBent Stem on valve (Stem is the portion of the valve the coil slides over)Air in system not allowing pilot operated check valve to open18

2621 South Daimler St.Santa Ana, CA. 92705Tel. 949.752.8818 Fax 949.756.1520www.ktihydraulicsinc.comDirectional Valve Not Shifting ProperlyBad Start SolenoidDirty Contacts in Hand ControlOOOOOOOOOOCylinder won't Retract Motor Under LoadStart Solenoid Stays OnWon't LowerWon't Lift Load (DC Motor Not Under Load)Won't Lift Load (DC Motor Under Load)Start Solenoid Just Clicks-Motor Not EngagingLoad Bounces When Cylinder RetractsStruggles to Lift LoadCylinder Extends With Unit Not OperatingReservoir OverflowsOOAeration of Hydraulic FluidCylinder Won't RetractOOExcessive Heat From UnitCylinder Won't ExtendOOWon't Hold LoadMotor Not RunningPossible CauseLow Battery VoltagePoor Ground ConditionCheck Hand ControlDebris in Load Holding ValveThermal Pressure LockCoil Not EnergizingBad Seals in CylinderLoose InletPacking on Cylinder Rod Worn OutHoses Connected BackwardsPump Not PrimingClogged OrificeRust In MotorBad DiodeCheck For Additional Valving On orConnected to CylinderNot Building PressureTrouble Shooting Quick Reference GuideOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOQuick Reference Guide covers the most common problems.(if we have missed a step please let us know)19OOOOOOOO

2621 South Daimler St.Santa Ana, CA. 92705Tel. 949.752.8818 Fax 949.756.1520www.ktihydraulicsinc.comSymptoms & Solutions Not Building Pressure –a. Gear pump not primingD/A Remove relief valve operate pump for a few seconds until fluid comesout of port replace relief valve.S/A Same as double acting but remove check valveb. Loose inlet on gear pumpc. Bad O-rings on relief valve or directional valveMotor Not Running a. Check Power to Start Solenoidb. Check for Power to DC Motorc. Check for Rust in DC Motor if a. & b. checked out okCylinder Won't Extend –a. Check Voltage @ Start Solenoid when trying to run Power Unit(Voltage May be below 9.5 volts)b. Check to see if power unit is bypassing over the relief valvec. Improper fluid in reservoir (viscosity to high)d. Check Directional Valve Section D/Ae. Check Packing on Cylinder SectionCylinder Won't Retract –a. Check to see if coil on load holding valve is activatingb. Check Directional Control Valve D/Ac. Pilot operated check valve not opening D/Ad. Low voltage or poor ground D/AExcessive Heat From Unit –a. Low Batteryb. Poor groundReservoir Overflows –a. Low Battery D/Ab. Poor Ground D/Ac. Air in hydraulic systemd. To small of reservoirStruggles to Lift Load –a. Low batteryb. Poor groundc. Gear pump sucking aird. Directional valve half shifting D/Ae. Debris in relief valve20

2621 South Daimler St.Santa Ana, CA. 92705Tel. 949.752.8818 Fax 949.756.1520www.ktihydraulicsinc.com Start Solenoid Just Clicks-Motor Not Engaging –a. Carbon buildup on contacts in start solenoidb. Rust inside motorc. Loose wire from start solenoid to DC motord. Cracked housing on start solenoidWon't Lift Load (DC Motor Not Under Load)a. Low fluid levelb. Loose inlet on gear pump (air being introduced into hydraulic System)c. Gear pump not primingD/A Remove relief valve operate pump for a few seconds until fluid comesout